Authors:

Eng. Abdulhakim Abdulwahid

Dr. Fawaz Noman

Eng. Nezar Haithm

Achieving the safety factor is very important in all vehicles including the Cars. More than 1.3 million people die every year as a result of road traffic accidents, and between 20 to 50 million people suffer from non-fatal injuries, according to United Nations statistics. Minimizing the effect of the impact of car accident can prevent a serious injury or could possibly prevent a deadly accident. The main objective of this study is to reduce the effect of the impact when car accident occurs. In order to make this possible was a suitable design and manufacture a mechanical device performing the external inversion (curling) of circular tubes under dynamic axial-force. Effect of the designed mechanical device on the tube inversion forming process is studied through applying the system and fix it in front of the car in order to absorb the impact of the accident. The effect of used the aluminum and copper tubes in the absorbing the energy is studied through applying the load that is generated by Universal Testing Machine (UTM) and ABAQUS simulation methods.   The results show that the 80 mm Copper tube with Die & Foam were satisfying because the amount of energy absorbed was much higher and twice comparing with the ordinary tubes.  It is therefore recommended that the 80 mm Copper tube with Die & Foam is suitable design and can be considered as an efficient energy-dissipating device since it provides favorable crashworthiness characteristics and excellent energy absorption capacity for optimum safety while preserving enhanced manufacturability.