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Based on the theoretical crashworthiness model of variable thickness rectangular section tubes, this article simplified the super-folding element to analyze the energy absorption characteristics of variable thickness 12 right-angles section (VTTRS) tubes during axial crushing. To discuss the deformation mode of VTTRS tubes, a series of finite element models were built based on the verified finite element model of variable thickness rectangle section tubes. Then, the deformation of VTTRS tubes was studied to obtain the structures deforming in stable mode which have a great performance in energy absorption. Meanwhile, a theoretical solution of the mean crushing force for VTTRS tubes was proposed and verified by establishing three groups of finite element models with different thicknesses and thickness gradients. Finally, a prediction for crash box was presented and the results showed the great potential of VTTRS tubes in energy absorption and explained the important role played by the theoretical model for vehicle during concept design stage.

A numerical and theoretical study on crushing behaviours of variable thickness 12 right-angles section tubes