This study aims to optimize the design parameters of a fiberglass filler circular crash box to enhance Energy Absorption (EA) capabilities under frontal loading conditions. Utilizing Response Surface Methodology (RSM) and a Box-Behnken Design (BBD), the research comprises 15 experiments to assess the impact of three primary parameters: foam diameter, foam height, and aluminum tube thickness. The optimal configuration achieved a maximum EA of 45.6002 kJ. The findings indicate that foam height significantly influences EA, and the interaction between foam height and tube thickness is crucial for optimizing crash box performance. This research also reveals significant interactions among design parameters, contributing to improved vehicle safety standards and crashworthiness. Consequently, the study underscores the importance of design optimization in enhancing vehicle safety, reducing the necessity for extensive physical testing, and ensuring effective energy dissipation during collisions. The results provide valuable insights for the future development of vehicle safety technologies.
Science Journal 