Experimental and numerical investigation of crash performances of additively manufactured novel multi-cell crash box made with CF15PET, PLA, and ABS

Abstract

In this study, a novel multi-cell crash box was designed and produced using 15 % short carbon fiber reinforced polyethylene terephthalate (CF15PET), polylactic acid (PLA), and acrylonitrile butadiene styrene (ABS) filaments using one of the additive manufacturing methods, the melt deposition method (FDM). All structures' maximum force and energy absorption performances have been investigated. As a result of the test, it was determined that the crash box, which best meets the high energy absorption and folding properties, one of the expected features in crash boxes, has parts manufactured using ABS and CF15PET materials. According to the test result, it was found that the energy absorption of the ABS crash box is 11 % higher than CF15PET and approximately 4.5 % higher than PLA. It has been determined that the maximum force response value of the ABS box is 5 % higher than CF15PET and 12 % higher than PLA. As a result, it has been determined that ABS and CF15PET materials can be used in crash boxes and can form an idea about the design and test result by designing and analyzing crash boxes using finite element programs.