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In this article, a new double-tapered rectangular tube (DTRT) with diaphragms is introduced as an energy absorber. The material tensile test and impact test were performed to verify the finite element model (FEM) of the tube. Based on the FEM, the Box–Behnken design (BBD) was applied to study the effects of diaphragm geometry on energy absorption (EA) and specific energy absorption (SEA). The weld length between the diaphragm and tube wall has positive effects on the EA and SEA of the DTRT, whereas the hole size on the diaphragms has negative effects. The optimal solution improved the EA and SEA by 12.01% and 9.29%, respectively. The conclusions of this study are based on engineering practice and are expected to aid engineers in designing the diaphragms of tubes as energy-absorbing structures.

Optimisation of double-tapered rectangular tube with O-shaped diaphragms as energy absorber