Multiobjective crashworthiness optimization of multi-layer honeycomb energy absorber panels under axial impact

•Multilayer honeycomb impact absorber introduced and design optimization is performed.•Foremost, theoretical design & optimization of multilayer honeycomb absorber handled.•Optimizing of min volume, max energy absorption & min impact shock level assumed.•Multilayer absorber design allows for design of more efficient absorber components.•More layers reduces stop distance and expands impact duration.

In this study, the design and optimization of a multi-layer configuration of hexagonal metal honeycomb energy absorber is performed using the genetic algorithm. It is assumed that the body structure with a predefined velocity impacts with barrier and the design objectives are to absorb whole kinetic energy besides limiting impact shock force. The response surfaces of honeycomb impact characteristics are extracted using finite element approach and then a honeycomb energy absorber is sized for case of a presumed impact problem. A multi-objective optimization technique is adopted to maximize the energy absorption capacity and to minimize the impact shock level while minimizing the total absorber size. A factorial design of experiment and response surface method is utilized to solve the optimization problem. The geometric specifications of honeycomb panels including the cell size, foil thickness, height and absorber face area for each layer of honeycomb panel are assumed as the design variables. Some optimization problems are handled and the optimized designs are compared to those from the literature wherever available.