Nowadays an automotive industry steadily has been growing and playing a major role on economy development for many years. The crash box is one of the most important parts for safety but it was found that the crash boxes manufactured domestically are not met international standard requirements. This is due to process and material limitation. This process for automotive safety test requires high budget and there is unclear approach for specific test. Therefore a study of crash boxes referred to energy absorption project was conducted as the alternative materials for product. Consequently this project was aimed to design and test crash boxes which made from the diversity of the alternative materials such as aluminum aluminum reinforced by foam resin reinforced by fiberglass resin reinforced by water hyacinth and resin reinforced by water hyacinth and husk. In addition it was also emphasized in studying energy absorption behavior and physical deformation of crash boxes after dynamic and static energy being applied. The experimental works were applied for these tests in partly referenced to US NCAP and ECE R29 standard for automobile collision test. Testing all types of crash boxes indicated that the aluminum reinforced by foam type was able to absorb energy at 189 MJ/m3. It is higher than resin reinforced by water hyacinth and husk at 1 MJ/m3 as 188 times. Furthermore the comparison of the energy absorption (per unit volume) between the aluminum reinforced by foam type and the steel type from the previous project equivalent 20 MJ/m3 found that it is 8.45 times of difference. While the front impact test was not successful because the size of crash boxes was not suitable for the energy volume. It was a cause for non-available calculation of energy absorption value.

The aim of this research is to create the center of mass testing machine for vehicles with maximum mass 3000 kilograms. By the performance of this machine is able to determine the center of mass 3 axis by horizontal longitudinal and vertical. On the other hand the verities of mass from 50 to 250 kilograms and the several of weight distribution at horizontal and longitudinal are applied to the condition of testing for reasonable to the position of the center of gravity for vehicle. The result of research discovered to the performance of center of mass tester was activated following to test conditions. Furthermore the position of the horizontal of center of gravity depends on the weight distribution at horizontal axis and an increasing of mass under non-uniform along the longitudinal and horizontal axis. In term of the position of the longitudinal of center of gravity the weight distribution at longitudinal axis and an increasing of mass rate are points. Otherwise the weight distribution at longitudinal axis and an increasing of mass are effect to the position of the vertical of center of gravity.

The aim of this research is to study the varieties of weight density distribution affect to the center of mass and vehicle stability. The weight density distribution tester was designed and changed the position of mass. Base on the center of mass is main points of vehicle stability. On the other hand FMCSA standard was applied to field test for considering of the brake performance and vehicle stability. The results of research discovered to the mass distribution on horizontal plane and fixed position Y1 are absolutely influence under an increasing 50 kilograms of mass condition. For the mass distribution on longitudinal plane and fixed position Z2 and Z3 are affected to the increasing of mass 100 and 150 kilograms respectively. Otherwise under an increasing of mass 200 and 250 kilograms there is non-influence to the weight density distribution. In term of the braking performance it’s depends on the lateral mass distribution especially the center position of mass installed on longitudinal and horizontal plane and close up on the front axle (Y2). For the vehicle stability results the position (Y2) is the highest influence for yaw rate and sideslip. Otherwise the position (Y3) or the position of mass installed on longitudinal plane and nearly at the left wheel on the rear axle. Additionally wheel lock-up condition was appeared on the front axle only. Because the behavior of the weight distribution on front axle was decreased lead to mass distribution on longitudinal plane.

Nowadays an automotive industry steadily has been growing and playing a major role on economy development for many years. The crash box is one of the most important parts for safety but it was found that the crash boxes manufactured domestically are not met international standard requirements. This is due to process and material limitation. This process for automotive safety test requires high budget and there is unclear approach for specific test. Therefore a study of crash boxes referred to energy absorption project was conducted as an alternative choice of testing. Regarding to the problems as addressed above this project was aimed to design and test crash boxes which come in various structures; simple type corrugated type and honeycomb type of crash box. In addition it was also emphasized in studying energy absorption behavior and physical deformation of crash boxes after dynamic and static energy being applied. Numeric simulation and static test methodology of front collision were applied for these tests in reference to USA NCAP standard for automobile collision test. Testing all types of crash boxes indicated that the corrugated type was able to absorb energy at 2.8% and 5.9% higher than honeycomb type and rectangular type respectively. This is capable to pick up stress and strain continually and effecting to more energy absorb than another type. Additionally this corrugated structure is feasible and suitable for crash box design in automotive manufacturing.