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Improving the crashing performance of energy-absorbing structure is of vital significance for the safety of subways. To this end, a new type of honeycomb-filled thin-walled energy absorber with axisymmetric thickness (HTEA-AT) was proposed. Unlike the honeycomb-filled thin-walled energy absorber with uniform thickness (HTEA-UT), the thicknesses of adjacent tube walls of HTEA-AT were defined as independent variables, while the thicknesses of the opposite walls remained identical. Numerical, theoretical and experimental methods were adopted to systematically investigate the crushing mechanics of the honeycomb-filled thin-walled energy absorber (HTEA). To improve the crashworthiness of HTEA-AT and HTEA-UT, a multi-objective optimization design (MOD) was carried out. The results revealed that HTEA-AT has a lower peak force and higher energy absorption than HTEA-UT, achieving superior crashworthiness performance. In addition, a multi-criteria decision-making method combining integrated entropy and gray relational analysis (GRA) was introduced to seek the ideal balance between the energy absorption ( EA ) and initial peak crushing force ( IPCF ) in the Pareto front. The optimized results indicated that the gray correlation was the largest at optimal point C, where  EA  and  IPCF  reached a balance ( EA  = 177.82 kJ,  IPCF  = 430.03 kN). This means that the optimized configuration can provide insightful information for the crashworthiness design of the energy-absorbing structure at the end of subways.

Crashing performance and multi-objective optimization of honeycomb-filled thin-walled energy absorber with axisymmetric thickness