Corrugated tubes absorbing impact energy in a vehicle collision

Crash Course: How Corrugated Square Tubes Are Revolutionizing Impact Absorption

Lena Kashyap in Tech & Innovation June 2025 • 3 min read.

"New research unveils the energy-absorbing superpowers of circumferentially corrugated square tubes, offering a safer future in transport and beyond."

In a world increasingly focused on safety and efficiency, the quest for better energy absorption technologies is never-ending. Whether it's protecting passengers in a car crash or safeguarding sensitive equipment during transit, the ability to effectively dissipate impact energy is paramount. Enter the circumferentially corrugated square tube (CCST), a novel design that's turning heads in engineering and materials science.

Traditional energy absorbers often rely on simple materials and structures, but these can be limited in their performance. Researchers have been exploring advanced geometries and materials to create more effective solutions. Thin-walled tubes, known for their excellent crashworthiness, have long been a staple in energy absorption applications. But what happens when you add corrugations and a unique profile? The results, as a recent study shows, can be quite remarkable.

A team of researchers has proposed a new take on thin-walled tubes, introducing a circumferentially corrugated square tube (CCST) with a cosine profile. This innovative design promises enhanced energy absorption capabilities, opening up new possibilities for safer vehicles, trains, and aerospace structures. Let's dive into the details of this groundbreaking research and explore how CCSTs are set to revolutionize impact protection.

What Makes These Corrugated Tubes So Special?

Corrugated tubes absorbing impact energy in a vehicle collision

The secret to the CCST's performance lies in its unique design, which is controlled by a cosine expression. This expression incorporates several key parameters:

The number of cosine wave crests (N): This determines the number of corrugations around the tube's circumference.

The amplitude (A): This dictates the depth of the corrugations.
The nominal side length (2Lo): This defines the overall size of the square tube.

By carefully adjusting these parameters, engineers can fine-tune the CCST's energy absorption characteristics to suit specific applications. But how do these parameters affect the tube's performance under impact?

The Future of Impact Protection?

The development of CCSTs represents a significant step forward in energy absorption technology. With their superior performance and customizable design, these corrugated tubes hold immense potential for enhancing safety in a wide range of applications. As research continues and manufacturing techniques advance, we can expect to see CCSTs playing an increasingly important role in protecting lives and property.

About this Article -

This article was crafted using a human-AI hybrid and collaborative approach. AI assisted our team with initial drafting, research insights, identifying key questions, and image generation. Our human editors guided topic selection, defined the angle, structured the content, ensured factual accuracy and relevance, refined the tone, and conducted thorough editing to deliver helpful, high-quality information.See our About page for more information.

This article is based on research published under:

DOI-LINK: 10.1016/j.tws.2018.11.028, Alternate LINK

Title: Energy-Absorption Characteristics Of A Circumferentially Corrugated Square Tube With A Cosine Profile

Subject: Mechanical Engineering

Journal: Thin-Walled Structures

Publisher: Elsevier BV

Authors: Zhixiang Li, Shuguang Yao, Wen Ma, Ping Xu, Quanwei Che

Published: 2019-02-01

Everything You Need To Know

What are circumferentially corrugated square tubes (CCSTs) and why are they gaining attention?

Circumferentially corrugated square tubes (CCSTs) are an innovative structural design featuring corrugations around a square tube. They're gaining attention for their superior energy absorption capabilities compared to traditional thin-walled tubes. This makes them ideal for enhancing safety in various applications, including vehicles, trains, and aerospace structures, where impact protection is crucial.

How do the design parameters of a circumferentially corrugated square tube (CCST) affect its energy absorption?

The energy absorption of a circumferentially corrugated square tube (CCST) is precisely controlled by its design parameters, which are incorporated into a cosine expression. Key parameters include the number of cosine wave crests (N), which dictates the number of corrugations; the amplitude (A), determining the depth of the corrugations; and the nominal side length (2Lo), which defines the overall size of the square tube. Adjusting these parameters allows engineers to fine-tune the CCST's energy absorption characteristics for specific applications and impact scenarios.

In what applications could circumferentially corrugated square tubes (CCSTs) be implemented to improve safety?

Circumferentially corrugated square tubes (CCSTs) show promise across several sectors requiring enhanced impact protection. They can be integrated into vehicles to improve crashworthiness, incorporated into train carriages to safeguard passengers during collisions, and used in aerospace structures to protect sensitive equipment. Their customizable design allows for tailored energy absorption, making them versatile for various safety applications.

What advantages do circumferentially corrugated square tubes (CCSTs) offer over traditional energy absorption methods?

Circumferentially corrugated square tubes (CCSTs) provide significant advantages over traditional energy absorbers, which often rely on simple materials and structures with limited performance. CCSTs, with their unique design controlled by a cosine expression incorporating parameters like the number of cosine wave crests (N), the amplitude (A), and the nominal side length (2Lo), offer superior and customizable energy absorption capabilities. This allows for more effective impact protection in various applications compared to traditional methods that may not be as adaptable or efficient.

What is the significance of the cosine profile in the design of circumferentially corrugated square tubes (CCSTs) and how does it contribute to their enhanced energy absorption?

The cosine profile in the design of circumferentially corrugated square tubes (CCSTs) is crucial for controlling the geometry and, consequently, the energy absorption characteristics of the tube. The cosine expression integrates key parameters such as the number of cosine wave crests (N), the amplitude (A), and the nominal side length (2Lo). By carefully adjusting these parameters within the cosine profile, engineers can precisely tailor the corrugations to optimize energy absorption for specific impact scenarios. This level of control allows CCSTs to outperform traditional thin-walled tubes in crashworthiness, making them a significant advancement in impact protection technology.