Numerical analysis of bio-inspired foam-filled multi-cell tapered tubes for energy absorption
Hamed Saeidi Googarchin, Shakib Sadeghi, Ali Keshavarzi
Abstract
This study investigates the crashworthiness of foam-filled multi-cell tapered tubes inspired by the biomechanical structure of the patella bone, aiming to enhance energy absorption in oblique impacts. A novel engineering formula is developed to predict the mean crush force by simplifying the foam-filled multi-cell tapered tubes into segmented, non-tapered single-cell tubes. The model accounts for the contributions of the hollow tube, foam filler, and their interaction, providing a comprehensive framework for estimating crashworthiness. The proposed formula is validated against numerical simulations and existing experimental data, demonstrating strong agreement and reliability. To further understand the behavior of these structures, a parametric study examines the effects of key design parameters, including taper angle, cell number, and load angle, on energy absorption and crushing efficiency. Results reveal significant improvements in mean crush force and crashworthiness performance with metal foam reinforcement, particularly at lower taper angles and higher cell numbers. Additionally, the transition angle and deformation mechanisms are analyzed to optimize structural stability and energy dissipation under oblique loads. The findings underscore the potential of bio-inspired foam-filled multi-cell tapered tubes as lightweight, efficient energy absorbers for automotive and structural applications. This work contributes to advancing the design and implementation of innovative crash energy management solutions.