A lattice-filled multicellular square tube features a regular cross-sectional shape, good energy consumption, and good crashworthiness, which is suitable for the design of energy absorbers in various protection fields such as automobiles, aerospace, bridges, etc. Based on the super folding theory, two reference planes are set to refine the energy consumption zone of the super folding element in this study. The energy consumption calculation of convex panel stretching is involved, and the critical crushing force formula is introduced in this study. Meanwhile, the calculation method from a single-cell square tube to a multicellular thin-walled square tube is extended and the structural optimization is investigated, in which the NSGAII algorithm is used to obtain the Pareto front (PF) of the crashworthiness performance index of the square multicellular tubes, the Normal Boundary Intersection (NBI) method is adopted to select knee points, and the influence of different cross-sectional widths on the number, as well as the thickness, of cells are discussed. This study's results indicate that the theoretical value is consistent with that obtained from the numerical simulation, meaning that the improved theoretical model can be applied to predict the crashworthiness of multicellular square cross-sectional tubes. Also, the optimization method and study results proposed in this study can provide a reference for the design of square lattice multicellular tubes.
Keywords: crashworthiness; multi-objective optimization; square lattice multicellular tubes; theoretical model.