De Biasio, AntonyGhasemnejad, HessamSrimanosaowapak, SWatson, JW2024-09-262024-09-262025-01De Biasio A, Ghasemnejad H, Srimanosaowapak S, Watson JW. (2025) Development of multi aluminium foam-filled crash box systems to improve crashworthiness performance of road Service vehicle. European Journal of Mechanics - A/Solids, Volume 109, January-February 2025, Article number 1054330997-7538https://doi.org/10.1016/j.euromechsol.2024.105433https://dspace.lib.cranfield.ac.uk/handle/1826/22965Honeycomb crash absorbers are known as mechanical energy-absorbing systems in both automotive and aerospace industries. However, the gap of knowledge in the transverse impacts of multi-foam-filled or stiffener-reinforced honeycombs is still unfilled. This paper investigates the energy absorption process in large crash boxes applied onto a road maintenance vehicle, exploring four aluminium honeycomb absorbers with design factors like added aluminium foam, corrugated sheet thicknesses, and stiffener reinforcements. The optimised foam-filled honeycomb structures are analysed for four crash scenarios in two different directions; frontal impact (T-direction) and lateral impact (L-direction) subjected to 50 km/h crash speed. The objective of this research is to identify the most efficient design that achieves a maximum acceleration of up to 20g while absorbing a specific energy of 145 kJ. The FE models were developed in ABAQUS to explore various scenarios related to damage zones, impact energy capabilities, and multi-foam-filled crash boxes. Finally, the lightest design of honeycomb absorbers which can maximise energy absorption while maintaining acceleration below the specified threshold of 20g will be recommended.enAttribution 4.0 Internationalhttp://creativecommons.org/licenses/by/4.0/40 Engineering4010 Engineering Practice and Education3 Good Health and Well Being7 Affordable and Clean EnergyMechanical Engineering & Transports4005 Civil engineering4017 Mechanical engineeringCrashworthinessHoneycombAluminium foamStiffener reinforcementsImpactDevelopment of multi aluminium foam-filled crash box systems to improve crashworthiness performance of road Service vehicleArticle552646105433109