Research Article

Crashworthiness Optimization a Novel Hexagonal Honeycomb Crash Box Under Crushing Test – A Numerical Study

Volume: 10 Number: 1 March 11, 2026

Crashworthiness Optimization a Novel Hexagonal Honeycomb Crash Box Under Crushing Test – A Numerical Study

Abstract

The crash box becomes a crucial component of the vehicle structure, special designed for energy-absorbing during collisions. This study aims to evaluate the performance of honeycomb structures in crash boxes and to investigate the deformation characteristics, energy absorption, and reaction force during crash tests. In this work, a novel crash box based on the hexagonal honeycomb structure with variations in the addition of circles at each hexagonal corner is proposed. The research configurations simulate a crushing test on the traditional honeycomb structure and variations CH 1, CH 2, CH 3 and CH 4. The honeycomb model was analyszed using different impactor velocity of 3 m/s and 4 m/s, with a mass of 500 kg. The result shows that increasing the size of the circle structures at each hexagonal honeycomb corner can increase crash energy absorption (EA). The CH 3 and CH 4 crash box structures offer the most increases in EA for each crash velocity than the traditional honeycomb. Higher impact velocities activate more stable progressive folding mechanisms in the honeycomb, thereby enhancing deformation efficiency during impact. The CH4 configuration exhibits higher SEA and MCF while maintaining a stable PCF, reflecting enhanced crashworthiness performance. This improvement is associated with progressive local buckling, which enables controlled and stable energy dissipation during impact. At a velocity of 3 m/s, the deformation pattern is consistent with previously reported studies, where the initial fold or fracture initiates in the middle of the honeycomb structure.

Keywords

References

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Details

Primary Language

English

Subjects

Automotive Safety Engineering, Automotive Engineering (Other)

Journal Section

Research Article

Publication Date

March 11, 2026

Submission Date

December 22, 2025

Acceptance Date

February 16, 2026

Published in Issue

Year 2026 Volume: 10 Number: 1

APA
Gustiani, D., Seçgin, Ö., & Demirer, A. (2026). Crashworthiness Optimization a Novel Hexagonal Honeycomb Crash Box Under Crushing Test – A Numerical Study. International Journal of Automotive Science And Technology, 10(1), 169-178. https://doi.org/10.30939/ijastech..1847010
AMA
1.Gustiani D, Seçgin Ö, Demirer A. Crashworthiness Optimization a Novel Hexagonal Honeycomb Crash Box Under Crushing Test – A Numerical Study. IJASTECH. 2026;10(1):169-178. doi:10.30939/ijastech.1847010
Chicago
Gustiani, Desi, Ömer Seçgin, and Ahmet Demirer. 2026. “Crashworthiness Optimization a Novel Hexagonal Honeycomb Crash Box Under Crushing Test – A Numerical Study”. International Journal of Automotive Science And Technology 10 (1): 169-78. https://doi.org/10.30939/ijastech. 1847010.
EndNote
Gustiani D, Seçgin Ö, Demirer A (March 1, 2026) Crashworthiness Optimization a Novel Hexagonal Honeycomb Crash Box Under Crushing Test – A Numerical Study. International Journal of Automotive Science And Technology 10 1 169–178.
IEEE
[1]D. Gustiani, Ö. Seçgin, and A. Demirer, “Crashworthiness Optimization a Novel Hexagonal Honeycomb Crash Box Under Crushing Test – A Numerical Study”, IJASTECH, vol. 10, no. 1, pp. 169–178, Mar. 2026, doi: 10.30939/ijastech..1847010.
ISNAD
Gustiani, Desi - Seçgin, Ömer - Demirer, Ahmet. “Crashworthiness Optimization a Novel Hexagonal Honeycomb Crash Box Under Crushing Test – A Numerical Study”. International Journal of Automotive Science And Technology 10/1 (March 1, 2026): 169-178. https://doi.org/10.30939/ijastech. 1847010.
JAMA
1.Gustiani D, Seçgin Ö, Demirer A. Crashworthiness Optimization a Novel Hexagonal Honeycomb Crash Box Under Crushing Test – A Numerical Study. IJASTECH. 2026;10:169–178.
MLA
Gustiani, Desi, et al. “Crashworthiness Optimization a Novel Hexagonal Honeycomb Crash Box Under Crushing Test – A Numerical Study”. International Journal of Automotive Science And Technology, vol. 10, no. 1, Mar. 2026, pp. 169-78, doi:10.30939/ijastech. 1847010.
Vancouver
1.Desi Gustiani, Ömer Seçgin, Ahmet Demirer. Crashworthiness Optimization a Novel Hexagonal Honeycomb Crash Box Under Crushing Test – A Numerical Study. IJASTECH. 2026 Mar. 1;10(1):169-78. doi:10.30939/ijastech. 1847010


International Journal of Automotive Science and Technology (IJASTECH) is published by Society of Automotive Engineers Turkey

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