Multi-Objective Optimization of the Crashworthiness of Aluminum Circular Tubes with Graded Thicknesses

This study proposes a novel graded-thickness, thin-walled aluminum alloy (Al) circular tube energy-absorbing structure and conducts comprehensive parametric modeling and multi-objective optimization research. The 7050Al tube was selected for analysis of its energy absorption characteristics via numerical simulations and drop-weight impact tests. Through simulation calculations and drop hammer impact verification tests, the number and location of concertina lobes after crushing, as well as the force variation law of the structure during the crushing process, were analyzed. The results indicate that generating annular folds at the impact end can significantly enhance impact absorption and suppress structural instability. Drop-weight test results further validate the superior crashworthiness of the proposed 7050Al tube under dynamic loading conditions and confirm the accuracy of the numerical crushing model. To enable rapid and precise structural modifications, a Python-based parametric modeling framework has been developed. A fully automated parametric optimization workflow has been established within Isight to facilitate the efficient, multi-objective optimization of the structure's design. This methodology provides a robust tool for designing customizable energy-absorbing structures with tailored crashworthiness performance.