This paper deals with the evaluation of the crashworthiness of thin-walled sandwich box structures for automotive applications. Quasi-static crushing simulations are carried out to estimate the energy absorption of prismatic box columns made from sandwich sheets. The sandwich sheets have perforated cores of different densities with staggered holes perpendicular to the panel faces. It is found that the specific energy absorption of columns made of sandwich sheets is approximately the same as that of conventional columns composed of homogeneous sheets of the same total wall thickness. Furthermore, theoretical analysis indicates that by increasing the core thickness, sandwich structures could be up to 50% lighter while providing the same mean crushing force. However, these gains may not be achieved in practical applications since increasing the core thickness also increases the likelihood of premature face sheet fracture during crushing.

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