Energy Absorption Efficiency of Crash Box Designs Analysis for NXGV Challenge 2025

Abstract

This study aims to develop and compare the effectiveness of two different crash box designs for the NxGV Challenge 2025 vehicle, focusing on enhancing safety and optimizing impact energy absorption. The crash box is a crucial component in electric vehicle (EV) safety systems, designed to absorb collision energy and minimize both driver injuries and structural damage. An efficient crash box reduces the force transmitted to the vehicle’s chassis, thereby improving overall crashworthiness. In this research, both crash box designs will be analyzed using HyperMesh for Finite Element Analysis (FEA) to evaluate their structural integrity and impact resistance. Physical impact tests will be conducted to validate simulation results. Both designs will utilize 2mm thick aluminum, selected for its lightweight properties, durability, and high energy absorption efficiency. The impact analysis will simulate a 325kg mass colliding at a velocity of 6.25m/s, representing realistic crash conditions. Performance evaluation will focus on maximum impact force, displacement, and energy absorption efficiency to determine the most effective design. The findings from this study are expected to contribute to the advancement of safer and more efficient crash box designs for lightweight electric race vehicles, with potential applications in real-world automotive safety improvements.