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Experimental and numerical investigation of crash performances of additively manufactured novel multi-cell crash box made with CF15PET, PLA, and ABS

  • Mehmet Kopar

    Mehmet Kopar received his BSc and MSc degrees from the Department of Automotive Engineering of Fırat University. In February 2021, he was continuing his doctoral education at Uludağ University Automotive Engineering Department within the scope of the 2,244 Industry Supported Program of the Scientific and Technical Research Council of Turkey (TUBITAK). He has been working on composite materials, artificial intelligence optimization, and additive manufacturing technologies.

    and Ali Rıza Yıldız

    Dr. Ali Rıza Yıldız is a Professor in the Department of Mechanical Engineering, Bursa Uludağ University, Bursa, Turkey. His research interests are the finite element analysis of structural components, lightweight design, vehicle design, vehicle crashworthiness, shape and topology optimization of vehicle components, meta-heuristic optimization techniques, and additive manufacturing.

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Published/Copyright: August 14, 2024
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Abstract

In this study, a novel multi-cell crash box was designed and produced using 15 % short carbon fiber reinforced polyethylene terephthalate (CF15PET), polylactic acid (PLA), and acrylonitrile butadiene styrene (ABS) filaments using one of the additive manufacturing methods, the melt deposition method (FDM). All structures’ maximum force and energy absorption performances have been investigated. As a result of the test, it was determined that the crash box, which best meets the high energy absorption and folding properties, one of the expected features in crash boxes, has parts manufactured using ABS and CF15PET materials. According to the test result, it was found that the energy absorption of the ABS crash box is 11 % higher than CF15PET and approximately 4.5 % higher than PLA. It has been determined that the maximum force response value of the ABS box is 5 % higher than CF15PET and 12 % higher than PLA. As a result, it has been determined that ABS and CF15PET materials can be used in crash boxes and can form an idea about the design and test result by designing and analyzing crash boxes using finite element programs.


Corresponding author: Ali Rıza Yıldız, Department of Mechanical Engineering, Bursa Uludag University, Bursa, Türkiye, E-mail:

Funding source: Bursa Uludağ University Scientific Research Projects Unit (BAP)

Award Identifier / Grant number: FGA-2022-1192

About the authors

Mehmet Kopar

Mehmet Kopar received his BSc and MSc degrees from the Department of Automotive Engineering of Fırat University. In February 2021, he was continuing his doctoral education at Uludağ University Automotive Engineering Department within the scope of the 2,244 Industry Supported Program of the Scientific and Technical Research Council of Turkey (TUBITAK). He has been working on composite materials, artificial intelligence optimization, and additive manufacturing technologies.

Ali Rıza Yıldız

Dr. Ali Rıza Yıldız is a Professor in the Department of Mechanical Engineering, Bursa Uludağ University, Bursa, Turkey. His research interests are the finite element analysis of structural components, lightweight design, vehicle design, vehicle crashworthiness, shape and topology optimization of vehicle components, meta-heuristic optimization techniques, and additive manufacturing.

  1. Research ethics: Not applicable.

  2. Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission.

  3. Competing interests: The authors state no conflict of interest.

  4. Research funding: None declared.

  5. Data availability: Not applicable.

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Published Online: 2024-08-14
Published in Print: 2024-09-25

© 2024 Walter de Gruyter GmbH, Berlin/Boston

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