An anti-collision and energy absorbing device is generally placed at the front end of railway vehicles to provide controlled collapse and sufficient energy absorbing capacity. In the conventional way, the energy absorbing device is usually designed as an integrated part of the carbody that can’t be easily replaced nor maintained after crash. To increase the maintainability and energy absorbing capacity of the energy absorbing device, a Multi-stage Crashworthiness Energy Absorbing Device has been developed, in which the first-stage and the second-stage energy absorbing units can be replaced or repaired under the collision that is not severe enough to initiate the third-stage energy absorbing unit. The Crashworthiness Energy Management (CEM) has four stages: coupler energy absorbing components (stage 1), honeycomb in the sliding center anti-climber (stage 2), metal peeling tubes mounted at the back of the fixed anti-climber (stage 3) and the structural components in the cab area (stage 4). By comparing the simulation results and test results, it is concluded that the finite element simulation model can provide dependable and accurate prediction for collision behaviors. Based on the design, simulation and test data, a safe, reliable and maintainable Multi-stage Crashworthiness Energy Absorbing Device has been verified and validated, which can provide valuable reference for researchers and engineers in the crashworthiness and railway vehicle industry.

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