Novel geometric arrangement effects on energy absorption of a conical structure with various cross-sections

In this research, the crushing behavior of interlocking 430 steel conical tubes with different arrangements and cross-sections in both experimental and numerical forms under quasi-static axial load was investigated. New samples were designed, by changing the number of layers, the arrangement of the layers and the geometry of the conical section. A total of seven different arrangements were designed in five different cross-sections (35 modes) and mass retention constant and energy absorption parameters were extracted for them. The non-linear Finite element method of simulation was performed using LS-Dyna software. To evaluate the accuracy of the simulation results, several experimental samples were made and tested by deep drawing method. As the number of layers increased, the amount of specific energy absorption (SEA) of the structure in different arrangements showed a different process, which emphasizes the importance of choosing the type of arrangement of layers for each structure. Also, increasing the number of layers does not necessarily increase the crush force efficiency (CFE), but how the layers are arranged is important. In samples with the same number of layers and the same arrangement, it was found that the change in the cross-section of the structure had a significant effect on the energy absorption of the samples. Choosing a suitable arrangement of the number of layers and their arrangement, while keeping the mass constant and reducing the space occupied for its installation, can improve the SEA up to 81% compared to a sample with improper and poor arrangement and geometry. SEA in a sample with three-layer design, circular cross-section and special arrangement was higher than other samples (21.8 J/g). •The effect of layering in conical structures was investigated by innovative layouts.•Proper selection of layer geometry and arrangement can increase the SEA up to 81%.•Samples P5-3-X (57.2%), H5-3-X (55.6%) and C5-3-X (53.9%) had the highest CFE values.•There is no linear trend in the SEA charts of this study.•Although the X and W share 3 layers, the X have the best and the W the worst CFEs.