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The energy absorbers we are exploring are designed, constructed, and manufactured from a special thermo-hardened aluminium alloy. Such a design allows for smaller dimensions and increased performance in the event of a crash. However, there are some specific impressions used in the design and construction of the energy-absorbing rod. These impressions act as “designed and desired deformation zones”. They can have different diameters and depths, and up to four of them can be manufactured on each rod. The number, diameters, and depths of these impressions can significantly influence the rod performance characteristics (such as peak crushing force, energy absorbed or maximum shortening).
In this article we present a comprehensive modelling methodology and results that confirm the optimal number of impressions in the energy absorbing rod and their dimensions. To do this, we first use correlation analysis to find the highest correlations for each independent variable (number, diameter and depth) and dependent variable (peak crushing force etc.). Based on these correlations, we model the optimal number of impressions using two approaches, both of which include not only the correlation between the independent and dependent variables but also the correlation between the dependent variables themselves.
The optimal number of impressions for an energy-absorbing rod, including the optimal impression dimensions is proposed. These results respect boundary and threshold limits suitable for both manufacturing and operation processes, covering safety, cost, and sustainability.
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