Finite element analysis and crashworthiness evaluation of a multi-stage aluminium alloy 6061-T6 impact attenuator for Formula SAE
DOI:
https://doi.org/10.58712/jerel.v5i2.219Keywords:
AA6061-T6 aluminium alloy, Crashworthiness, Energy absorption, Finite Element Analysis (FEA), Formula SAE, Impact attenuatorAbstract
Formula SAE regulations require every prototype vehicle to be equipped with an impact attenuator as a passive safety system capable of absorbing a minimum frontal impact energy of 7,350 J at an impact velocity of 7 m/s for a vehicle with a mass of approximately 300 kg. This study aims to design an impact attenuator that satisfies the Formula SAE requirements to improve vehicle crashworthiness. Three design variations were analyzed using Finite Element Analysis (FEA) with LS-DYNA to evaluate energy absorption, impact force, acceleration/deceleration, and displacement. The accuracy of the numerical model was validated using previously published experimental data before analyzing the effect of thickness variation in each stage of the impact attenuator. The simulation results show that the optimum design is capable of absorbing impact energy above the minimum requirement of 7,350 J, exhibits a high Crash Force Efficiency (CFE), produces acceleration within the prescribed safety limits, and provides controlled deformation during the impact process. The results indicate that the proposed impact attenuator design satisfies the Formula SAE safety requirements and has the potential to be applied to prototype vehicles to improve safety performance during frontal collisions.
References
Abramowicz, W., & Jones, N. (1986). Dynamic progressive buckling of circular and square tubes. International Journal of Impact Engineering, 4(4), 243–270. https://doi.org/10.1016/0734-743X(86)90017-5
Arora, P., & Venkatachalam, G. (2022). Design and Simulation of a Formula SAE Impact Attenuator. SAE International Journal of Materials and Manufacturing, 15(3), 05-15-03–0018. https://doi.org/10.4271/05-15-03-0018
ASM Handbook Committee. (1990). Properties and Selection: Nonferrous Alloys and Special-Purpose Materials. ASM International. https://doi.org/10.31399/asm.hb.v02.9781627081627
Athafarras, M., Djamari, D. W., Fikri, M. R., Budiman, B. A., Triawan, F., & Veza, I. (2022). Development of impact attenuator analysis tools in crash scenario using Euler method and finite element analysis. Journal of Engineering and Applied Science, 69(1), 2. https://doi.org/10.1186/s44147-021-00058-0
Belingardi, G., & Obradovic, J. (2010). Design of the Impact Attenuator for a Formula Student Racing Car: Numerical Simulation of the Impact Crash Test. Journal of the Serbian Society for Computational Mechanics, 4(1), 52–65. https://www.sscm.kg.ac.rs/jsscm/downloads/Vol4No1/Design_of_the_Impact_Attenuator_for_a_Formula_Student_Racing_Car.pdf
Boria, S. (2010). Behaviour of an impact attenuator for formula SAE car under dynamic loading. International Journal of Vehicle Structures and Systems, 2(2). https://doi.org/10.4273/ijvss.2.2.01
Hermawan, M. V., Choiron, Moch. A., Purnowidodo, A., & Winarto, W. (2025). Effect of Tube Thickness Configuration of Two Segments Circular Crash Box on Its Crashworthiness Performance. Automotive Experiences, 8(1), 189–204. https://doi.org/10.31603/ae.13170
Jones, N. (2011). Structural Impact. Cambridge University Press. https://doi.org/10.1017/CBO9780511820625
Kaya, D., & Özyurt, E. (2022). Design and optimization of impact attenuator for a Formula SAE racing car. Sigma Journal of Engineering and Natural Sciences – Sigma Mühendislik ve Fen Bilimleri Dergisi, 40(2), 390–401. https://doi.org/10.14744/sigma.2022.00041
Prasetya, L. W., Prabowo, A. R., Ubaidillah, U., Hadi, S., Hidajat, R. L. L. G., Tuswan, T., & Adiputra, R. (2021). Crashworthy Examination of a Newly Proposed Impact Attenuator Design: Experimental Testing and Numerical Analysis. Modelling and Simulation in Engineering, 2021, 1–20. https://doi.org/10.1155/2021/5001060
Reid, S. R., & Harrigan, J. J. (1998). Transient effects in the quasi-static and dynamic internal inversion and nosing of metal tubes. International Journal of Mechanical Sciences, 40(2–3), 263–280. https://doi.org/10.1016/S0020-7403(97)00054-4
Rogala, M., & Gajewski, J. (2023). Crashworthiness Analysis of Thin-Walled Square Columns with a Hole Trigger. Materials, 16(11), 4196. https://doi.org/10.3390/ma16114196
Rooppakhun, S., Boonporm, P., & Puangcha-um, W. (2015, March 30). Design and Analysis of Impact Attenuator for Student Formula. https://doi.org/10.4271/2015-01-0094
SAE International. (2024). Formula SAE Rules 2025. https://www.fsaeonline.com/cdsweb/app/NewsItem.aspx?NewsItemID=379e4a8a-80a2-4a74-87c2-6f2de4212270
Segade, A., López-Campos, J. A., Fernández, J. R., Casarejos, E., & Vilán, J. A. (2016). Finite element simulation for analysing the design and testing of an energy absorption system. Materials, 9(8). https://doi.org/10.3390/ma9080660
Vettorello, A., Campo, G. A., Goldoni, G., & Giacalone, M. (2020). Numerical-experimental correlation of dynamic test of a honeycomb impact attenuator for a formula sae vehicle. Metals, 10(5). https://doi.org/10.3390/met10050652
Xie, S., Zheng, S., Zhang, J., Liu, Z., & Zhou, H. (2023). The design of circular tubes with stepped varying thicknesses and their synergistic multi-tube combination. Structures, 57, 105125. https://doi.org/10.1016/j.istruc.2023.105125
Downloads
Published
Issue
Section
License
Copyright (c) 2026 Aditia Pratama, Zainal Abadi, Delima Yanti Sari, Wanda Afnison
This work is licensed under a Creative Commons Attribution 4.0 International License.
How to Cite
