Reducing weight of vehicles is considered as one of the most effective ways to improve fuel economy. In vehicle lightweight design, it is vital that crashworthiness must not be compromised. For the purpose of improving crashworthiness, various structures have been proposed. However, many of those bring significant complexity and challenges in terms of manufacturing.
The hot form quench (HFQ) forming process is capable of forming aluminium alloy blanks with highly complex profiles. This work focuses on the crashworthiness of HFQ vehicle components with corrugated features. In the present study, The corrugations are implemented on the A-pillar components. Using LS-DYNA simulations, the response of Honda Accord 2011 model under the IIHS 25% small overlap frontal crash test condition is analysed. Comparison is made among three configurations (baseline and two types of corrugations). A parametric study on the gauge thickness is also carried out, in order to assess the potential of mass saving. It is found that corrugations can effectively increase resistance of thin-walled structure to bending loads, and consequently effectively reduce the mass of A-pillar without compromising safety performance.