The main objective of this research is improving the design and performance of the polyurethane foam-filled thin-walled aluminum grooved circular tubes. The tubes are shaped with the inner and the outer circular grooves at different positions along the axis. In this study, the effects of the grooves distance, tube diameter, grooves depth, foam density, and tube thickness are investigated on the Specific Energy Absorption (SEA) of grooved circular tubes. finite-element analysis (FEA) and response surface methodology (RSM) is carried out for crush force efficiency. Finite-element analysis is performed with design of experiments technique (DOE) at the different combinations of the design parameters. The results of RSM indicate that SEA is related to the grooves distance, tube diameter, tube thickness of the groove and groove depth, by a quadratic model. Moreover, the effects of the interaction between the grooves distance - the foam density and the grooves distance - the tube diameter on the SEA was significant.
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