Analysis and optimisation of parameters influencing the out-of-plane energy absorption of an aluminium honeycomb

To improve the efficiency of the numerical simulation of the crushing of a honeycomb structure, the equivalent solid model of an aluminium honeycomb core was established. Comparison between the numerical simulation results and experimental evidence revealed that the numerical model of the honeycomb structure was effectively verified as representative. Secondly, the response surfaces for the variation of specific energy absorption (SEA) with side length l and thickness t of the aluminium foil were constructed by surrogate models. Then the relationship between SEA variation and the length l and thickness t of the aluminium foil was investigated. Results indicated that SEA increased with increasing t and decreased with increasing l. The optimum SEA and associated structural parameters (l=1.0mm, and t=0.16mm) of an aluminium honeycomb were obtained. •The article aims to analyse and optimise honeycomb structures for crashworthiness.•Equivalent solid model of honeycomb structure was verified by compression test.•Surrogate models of specific energy absorption were established.•Relationship of SEA variation with aluminium foil parameters was investigated.•Optimum SEA and honeycomb structure parameters were obtained.