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Abstract The Simplified Super Folding Element theory (SSFE) has been applied to predict the mean axial crush force of a wide range of aluminium extrusions with rather complex cross sections. The results from the SSFE theory have been compared with finite element (FE) simulations and experimental tests. It was found that in most cases the SSFE theory was able to predict the value of the mean force within ± 10% of the FE simulations and ± 20% when comparing with experiments. This makes the SSFE theory a valuable tool in the initial stages of crash box design and to some extent reduces the excessive and time-consuming use of FE analyses.
Hanssen et al. (Mon,) studied this question.