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Crashworthiness Evaluation of a Parallel 5-Tube Circular Multi-Segment Crash Box with Cutting Die Trigger for Railway Safety

Automotive Experiences · Vol. 8 No. 3 (2025) · hlm. 683–702

DOI
10.31603/ae.14952
ISSN
2615-6636, 2615-6202
Terbit
2025-12-27
Penerbit
Universitas Muhammadiyah Magelang
Bahasa
en

Abstrak

This study presents a crashworthiness evaluation of a Parallel 5-Tube Circular Multi-Segment Crash Box with a cutting die trigger, designed to promote controlled progressive folding for high-speed railway applications. The crash box integrates four primary tubes and one secondary tube in a parallel configuration, featuring multi-segment wall thickness and a die-trigger mechanism designed to initiate controlled folding from the tube’s end. The die acts as a deformation initiator, guiding the folding sequence to occur progressively, thereby improving energy dissipation and reducing peak impact forces. Two impact models, namely the Cutting Die Model (CDM) and the Flat Model (FM), were employed to investigate the combined effects of trigger mechanism, multi-segment wall thickness, and impact direction using validated finite element simulations supported by quasi-static and drop-test experiments. Finite Element Analysis (FEA) simulations using ANSYS LS-DYNA were conducted to assess key crashworthiness indicators, including maximum crushing force (Fmax), energy absorption (EA), specific energy absorption (SEA), mean crushing force (Fmean), and crushing force efficiency (CFE). Experimental validation through quasi-static and drop tests confirmed the reliability of the simulation results. The findings reveal that the CDM configuration significantly outperforms the FM model, exhibiting lower Fmax and higher EA, SEA, and CFE values. Progressive folding initiated by the die mechanism enables more stable and efficient energy dissipation. Additionally, the impact direction influences deformation behavior, with the t₁”“tâ‚‚ configuration yielding superior performance. These results demonstrate the effectiveness of the proposed crash box design in meeting the stringent safety and spatial requirements of modern railway systems.

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  • Yogyakarta State University
  • Hasanuddin University
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Rekan penulisOrganisasiArtikel bersama
Sabar NurohmanYogyakarta State University1
A. Masrurah AswidyaningratAfiliasi tidak diketahui1
Yuninda AdumirantiAfiliasi tidak diketahui1
Ridwan RidwanHasanuddin University1
Willy Artha WirawanAfiliasi tidak diketahui1
Bambang JunipitoyoAfiliasi tidak diketahui1
Setyo Hariyadi Suranto PutroAfiliasi tidak diketahui1
A’yan SabitahAfiliasi tidak diketahui1
Ahmad Hamim SuudyAfiliasi tidak diketahui1
Yulmira YantiAfiliasi tidak diketahui1
Hasmiandy HamidAfiliasi tidak diketahui1
Yaherwandi YaherwandiAfiliasi tidak diketahui1

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Sumber metadata: OAI-PMH (metadata jurnal) http://journal.unimma.ac.id/index.php/AutomotiveExperiences/oai, pertama di-harvest 8 Nov 2026, terakhir terlihat 8 Nov 2026.
Metadata asli (oai_dc) 
<oai_dc:dc xmlns="http://www.openarchives.org/OAI/2.0/" xmlns:dc="http://purl.org/dc/elements/1.1/" xmlns:oai_dc="http://www.openarchives.org/OAI/2.0/oai_dc/" xmlns:xsi="http://www.w3.org/2001/XMLSchema-instance" xsi:schemaLocation="http://www.openarchives.org/OAI/2.0/oai_dc/  http://www.openarchives.org/OAI/2.0/oai_dc.xsd">
	<dc:title xml:lang="en">Crashworthiness Evaluation of a Parallel 5-Tube Circular Multi-Segment Crash Box with Cutting Die Trigger for Railway Safety</dc:title>
	<dc:creator xml:lang="en">Hermawan, Muhammad Vendy</dc:creator>
	<dc:creator xml:lang="en">Choiron, Moch. Agus</dc:creator>
	<dc:creator xml:lang="en">Purnowidodo, Anindito</dc:creator>
	<dc:creator xml:lang="en">Winarto, Winarto</dc:creator>
	<dc:subject xml:lang="en">Energy dissipation</dc:subject>
	<dc:subject xml:lang="en">Crash energy optimization</dc:subject>
	<dc:subject xml:lang="en">Passive safety enhancement</dc:subject>
	<dc:subject xml:lang="en">Structural deformation control</dc:subject>
	<dc:subject xml:lang="en">Crash simulation modeling</dc:subject>
	<dc:description xml:lang="en">This study presents a crashworthiness evaluation of a Parallel 5-Tube Circular Multi-Segment Crash Box with a cutting die trigger, designed to promote controlled progressive folding for high-speed railway applications. The crash box integrates four primary tubes and one secondary tube in a parallel configuration, featuring multi-segment wall thickness and a die-trigger mechanism designed to initiate controlled folding from the tube’s end. The die acts as a deformation initiator, guiding the folding sequence to occur progressively, thereby improving energy dissipation and reducing peak impact forces. Two impact models, namely the Cutting Die Model (CDM) and the Flat Model (FM), were employed to investigate the combined effects of trigger mechanism, multi-segment wall thickness, and impact direction using validated finite element simulations supported by quasi-static and drop-test experiments. Finite Element Analysis (FEA) simulations using ANSYS LS-DYNA were conducted to assess key crashworthiness indicators, including maximum crushing force (Fmax), energy absorption (EA), specific energy absorption (SEA), mean crushing force (Fmean), and crushing force efficiency (CFE). Experimental validation through quasi-static and drop tests confirmed the reliability of the simulation results. The findings reveal that the CDM configuration significantly outperforms the FM model, exhibiting lower Fmax and higher EA, SEA, and CFE values. Progressive folding initiated by the die mechanism enables more stable and efficient energy dissipation. Additionally, the impact direction influences deformation behavior, with the t₁”“tâ‚‚ configuration yielding superior performance. These results demonstrate the effectiveness of the proposed crash box design in meeting the stringent safety and spatial requirements of modern railway systems.</dc:description>
	<dc:publisher xml:lang="en">Universitas Muhammadiyah Magelang</dc:publisher>
	<dc:date>2025-12-27</dc:date>
	<dc:type>info:eu-repo/semantics/article</dc:type>
	<dc:type>info:eu-repo/semantics/publishedVersion</dc:type>
	<dc:format>application/pdf</dc:format>
	<dc:identifier>https://journal.unimma.ac.id/AutomotiveExperiences/article/view/14952</dc:identifier>
	<dc:identifier>10.31603/ae.14952</dc:identifier>
	<dc:source xml:lang="en">Automotive Experiences; Vol. 8 No. 3 (2025); 683-702</dc:source>
	<dc:source>2615-6636</dc:source>
	<dc:source>2615-6202</dc:source>
	<dc:language>en</dc:language>
	<dc:relation>https://journal.unimma.ac.id/AutomotiveExperiences/article/view/14952/6408</dc:relation>
	<dc:rights xml:lang="en">Copyright (c) 2025 Muhammad Vendy Hermawan, Moch. Agus Choiron, Anindito Purnowidodo, Winarto Winarto</dc:rights>
</oai_dc:dc>