Crashworthiness optimization of foam-filled tailor-welded tube using coupled finite element and smooth particle hydrodynamics method

This paper has presented the optimal design for empty and foam-filled tailor welded tubes (TWTs). Specific energy absorption, peak force and crushing force efficiency (CFE) were used to determine energy absorbing capacity in empty and foam-filled tubes using both finite element and smooth particle hydrodynamics methods. Numerical results showed that SEA and peak force increased with increasing thickness of upper part and foam density while peak forces were significantly low in TWTs made from different materials. Moreover, CFE decreased with increasing thickness of upper part and with decreasing welding location whereas CFE slightly increased with increasing foam density.

► Crashworthiness behavior was determined by using coupled FE and SPH method.
► SEA and peak force increased with increasing upper part thickness and foam density.
► Peak forces were significantly low for TWTs made from different materials.
► CFE decreased with increasing upper part thickness and decreasing welding location.
► CFE slightly increased with increasing foam density.