From Experimental Investigation to Optimized Design: A Time-efficient Methodology for Carbon Fiber Composite Crash Structures in Formula Student Applications

This study presents the design and numerical validation of a composite impact attenuator, with Formula Student serving as a proof of concept. The research methodology involved an initial calibration phase, where simulations of simple test geometries were iteratively refined to match experimental data from dynamic tests within a 1% error margin. These validated material parameters were then applied to a final impact attenuator design featuring a five-tube configuration. To enhance time and cost efficiency, physical testing was conducted only at the intermediate component level, where simulation models were calibrated. The final crash structure was then optimized entirely through virtual simulations, eliminating the need for full-scale physical prototyping. Finite element simulations demonstrated that the proposed structure meets established deceleration and energy dissipation criteria with a significant safety margin. Additionally, compared to a commercially available aluminum honeycomb attenuator, the composite design achieved equivalent energy absorption characteristics while reducing weight by 13%. These findings validate the proposed methodology and highlight the advantages of composite crash structures for high-performance applications.