| Summary: | To increase the energy-absorbing capability of frontal collision management systems and raise vehicle crash safety, foam-filled crash boxes should be optimized. On the basis of a double tubular construction, a novel foam-filled crash box with different design is developed. The energy absorption capacity, initial peak force and deformation modes of the original and improved crash boxes were examined using impact models. As opposed to the full-filling design, it is demonstrated that the filling design may utilize less foam while increasing specific energy absorption. The stability of the continuing deformation after the first buckling is determined by the foam filled crash-box combined. For the foam-filled crash box, a better optimized design technique is suggested using Radial Basic Function and Non-dominated Sorting GA II. Compression tests are used to validate the design concept. Therefore, the optimal design technique of the crash box is suitable and practical for the crashworthiness design of crash boxes, taking consideration the combined effect of significant indicators for electric vehicle.
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