The present paper concerns the development of crash-worthiness maximization techniques for tubular structures, and the applications to the axial crushing problems of cylindrical tubes as well as square tubes. In the program system presented in this study, an explicit finite element code. DYNA3D is adopted for simulating complicate crushing behavior of tubular structure for each design point which is arranged by using the technique of design-of-experiment. Based on the numerical analyses, a response surface approximation technique is applied to construct an approximated design sub-problem in the preassigned design space. The approximated sub-problem is then solved by the usual mathematical programming technique (DOT). These optimization processes is repeated until the given con-vergence conditions will be satisfied. Also, a comparison of crushing energy absorption between cylindrical tubes and square tubes is discussed. Furthermore, a series of aluminum cylindrical tubes are tested under axial impact condition for the experimental validation of the numerical solutions.
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