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Crash boxes as a passive safety system in vehicles had been developed to produce high energy absorption performance. This study investigates the influence of cross-section geometry and fibre orientation angle on the composite crash box design to determine deformation pattern and energy absorption performance. The cross sections studied are circles and squares with variations in fibre orientation angles 0°, 15°, 30°, 45°, 60° and 75°. Carbon Fibre Epoxy CFS003 / LTM25 Prepegs with the type of plain woven fibre used to model crashbox structures. The computer simulation test model was carried out using a frontal load model with velocity of 7.76 m s −1 . The results showed a circle cross-section at each variation of the orientation angle has a higher energy absorption than a square cross-section. Deformation patterns in each model show different characteristics including fragmentation mode, lamina bending, brittle fracturing, and local buckling as well as a combination of several patterns. The highest energy absorption obtained in the C60 model was 3.664 kJ with Specific Energy Absorption (SEA) of 36.799 kJ kg −1  and a CFE value of 0.59. While the lowest energy absorption occurs in the S45 model with 1.287 kJ which has a SEA value of 12.667 kJ kg −1 with a CFE of 0.49. The CFE value indicates that the model with a circular cross section has better crushing stability than a squarecross section.

Energy absorption and deformation pattern analysis of carbon fibre reinforced composite crash box under frontal load model