Computational Analysis of Triply Periodic Minimal Surface Based Honeycomb Structures Under Impact Loading

Abstract

Balancing lightweight structural design with adequate crashworthiness performance remains a fundamental engineering challenge in automotive crash management. Conventional crash bars exhibit inherent limitations under dynamic loading, including localised deformation and inconsistent force transmission, motivating research into alternative cellular architectures. This thesis presents a computational investigation comparing two TPMS-derived 2D crash bar architectures, namely the G-Honeycomb and P-Honeycomb, against a conventional hollow cylindrical crash bar. Finite element models were developed in SolidWorks and analysed using Abaqus/Explicit, with all configurations assigned AA6061-T6 aluminium alloy properties via a rate-independent elastic-plastic constitutive model. Simulations were conducted at impact velocities of 40 km/h and 60 km/h under identical boundary conditions. The G-Honeycomb produced the highest crush force efficiency and the most stable, broadly distributed deformation pattern across both test velocities. The P-Honeycomb generated a substantially higher initial peak force and exhibited a reduction in energy absorption with increasing velocity, consistent with a velocity-induced change in collapse mechanism. The conventional crash bar demonstrated concentrated plastic hinge formation with limited structural participation, resulting in comparatively low force efficiency that deteriorated further at higher velocity. These results suggest that the G-Honeycomb represents a viable alternative for automotive crash bar applications and highlight the importance of dynamic validation when evaluating TPMS-derived 2D structures intended for impact-critical engineering applications.