Design of a New Vehicle Front End Structure to Optimise Crashworthiness

Mohab Elmarakbi, Madeleine Combrinck, Ahmed Elmasry, Ahmed Elmarakbi

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review


Within this paper methods in reducing weight and optimizing the front-end structure, by specifically targeting both new materials and redesigning the cashbox, to improve crashworthiness were investigated. This was accomplished through redesigning the cross-sectional shape of the crash box, trigger location and type of trigger used, and the use of different materials. The optimal crash box design was found to be a hexagonal prism that incorporated a central trigger which reduced the thickness from 2mm to 1mm. Moreover, the ideal material was identified to be SGF/PA6/GnPls. When this optimized crash box was incorporated to the front-end structure and the ideal material applied to the bumper beam, the fully optimized front-end structure reduced the weight by 75%, reduced peak force by 28% and increased specific energy absorption by 94% and 55% for a frontal and side collision respectively.
Original languageEnglish
Title of host publicationProceedings of the ASME 2022 International Mechanical Engineering Congress and Exposition. Volume 9: Mechanics of Solids, Structures, and Fluids; Micro- and Nano-Systems Engineering and Packaging; Safety Engineering, Risk, and Reliability Analysis; Research Posters. Columbus, Ohio, USA. October 30–November 3, 2022.
PublisherAmerican Society of Mechanical Engineers (ASME)
Number of pages11
ISBN (Electronic)9780791886717
Publication statusPublished - 30 Oct 2022


Dive into the research topics of 'Design of a New Vehicle Front End Structure to Optimise Crashworthiness'. Together they form a unique fingerprint.

Cite this