Crashworthiness analysis of foam filled star shape polygon of thin-walled structure

This paper aims to fabricate star polygon thin walled energy absorption structure that tends to relapse the intensity of set in decelerations during impact while escalating the amount of energy absorbed. The crashworthiness topology optimization is used for structural optimization of various foam-filled tubes. The relative advantages of 14 configurations are discussed, and the effects of filling five types of foam into the best configuration of the star-shaped tube over an empty one is investigated. Specific Energy Absorption, Peak Crush Force and response of weight of the members during frontal impact are the main dimensions parameters of the member's performance. Numerical simulation is carried out using the explicit dynamics of Ansys 17.1, and obtained results are compared with experimental results conferring crash behavior and energy absorption characteristics. Based on results, the suited configuration with required performance in crashworthiness is suggested, which shall be incorporated in automobiles for safety consideration of passengers during an impact. The results show an increment of 40% in Specific Energy Absorption suggesting a better choice of a particular type of foam over a hollow tube. •Discovering of a star shaped polygon as a thin walled energy absorbing tube to be utilised in automobile chassis.•Structural Optimization performed to get the best configuration of star shape for increasing specific energy value.•Incorporation of 5 different types of foam in the star shaped tube (n = 8) with varying densities.•Foam with the optimum density has been selected with the most appropriate energy absorbing capacity.•Increase in crushing parameters such as mean crushing load and specific energy value using the combined structure.