Crash behavior of a 3D S-shape space frame structure

In order to ensure enough passenger space and reduce the damage of occupants during a car front collision, it is necessary to understand the crushing behavior and to improve the energy absorption capability of space frame structures. In this study, the crushing behavior of a 3D S-shape extruded aluminum square frame with 45° curvature angle (α) and 45° rotation angle (β) is studied under an axial loading. Different cross-section reinforcements (parallel and diagonal internal lateral support profiles) and aluminum foam-filled reinforcement are discussed. The effectiveness of reinforcement is assessed using the specific energy absorption and the peak force. Based on the numerical analyses, the left diagonal reinforced structure shows the highest specific energy absorption (SEA = 3.813 J/g). This is 277% of the SEA of the empty column structure (SEA = 1.375 J/g). In addition, the aluminum foam-filled reinforcement increases the energy absorbed by the 3D space frame structure by an additional 78%. The results show that aluminum foam is an efficient alternative energy absorber. However, it does not increase the SEA of the structure due to the increased mass and increases the peak force significantly.