Occupant safety has become increasingly important in the recent times. At the instance of an accident or collision, structures with high energy absorption can provide better occupant safety. Thin-walled tubes are widely used as energy absorbers in automobiles and other structures. In the present work, crashworthiness characteristics of double wall empty and double wall foam filled tubes are investigated. Thin wall extruded aluminum square tubes are used in this study. Polymer foam of three different densities, viz., 40 kg/m3, 80 kg/m3, 140 kg/m3 was used as filler material between the two tubes to fabricate a double wall foam filled tube. Both parallel and diamond configurations were considered for double walled empty and foam filled configurations. All the specimens were compressed at a displacement rate of 100 mm/min. Crushing of different configurations was numerically analyzed using nonlinear finite element tool LS-Dyna®. In double wall empty configuration, diamond arrangement absorbed more energy compared to parallel due to the interaction between inner and outer tubes. Results indicate that energy absorption increases with the filling of foam. Compared to double wall tubes, the maximum increase in energy absorption of ∼ 50% is observed in foam filled tubes. Using Computed Tomography (CT) scan of specimens, it is observed that foam filling alters the crushing behavior of the inner and outer tubes.

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