Optimised design of nested oblong tube energy absorbers under lateral impact loading

Dynamic lateral crushing of mild steel (DIN 2393) nested tube systems was conducted using a ZWICK ROELL impact tester. The tests were performed with impact velocities ranging between 3 and 5 m/s, achieved using a fixed mass impinging onto the specimens under the influence of gravity. The various nested tube systems consisted of one standard and one optimised design. Their crushing behaviour and energy absorption capabilities were obtained and analysed.In addition to the experimental work, numerical simulations using the explicit code LS-DYNA were conducted; boundary conditions matching those observed in experiments were applied to the models. Results from the numerical method were compared against those obtained from experiments. An over-prediction in force–deflection responses was obtained from the numerical code. An attempt was made to explain this inconsistency on the basis of the formation of plastic hinges and the validity of strain rate parameters used in the Cowper Symonds relation. It was found that the optimised energy absorbers exhibited a more desirable force–deflection response than their standard counterparts due to a simple design modification which was incorporated in the optimised design.