A square honeycomb-filled thin-wall composite structure is proposed, and the crashworthiness of honeycomb filled structure and corresponding unfilled (thin-walled empty tube) structures under 12 kinds of impact conditions are systematically studied by experimental research and numerical analysis. At the same time, numerical optimization design of honeycomb filled structure is carried out by combining Kriging approximation technique and small population genetic algorithm. The results show that under various impact conditions, the energy absorption of the honeycomb filled structure is higher than that of the thin-walled empty tube structure, and the impact angle and velocity have significant effects on the energy absorption performance of the honeycomb filled structure. At the same impact velocity, the energy absorption of the honeycomb filled structure decreases as the impact angle increases. At the same impact angle, the energy absorption of the filled structure increases as the impact velocity increases. The Kriging approximation technique and the small population genetic algorithm optimize the optimal parameter matching of the honeycomb filled structure obtained by optimizing the honeycomb filled structure, which can improve the energy absorption of the honeycomb filled structure.
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