A comparison of optimization values for empty aluminum circular tubes and double circular tubes containing foam under flexible loading is presented in this paper. Thin-walled tube is widely used in the vehicle structure for impact mitigation especially on the vehicle door. In this study, AA6063 T6 aluminum alloy tubes were filled with foam with both ends supported and subjected to quasi-static bending. Finite Element (FE) modeling and analysis has been performed using finite element software. The developed FE model has been experimentally validated and good agreements have been observed between experiment and simulation results. The deformation of the tube under bending load was studied with variations in thickness (t) and diameter (d) of the tube wall. The design of various objective optimization (multi objective optimization) is developed with considering two crashworthy performance that conflicting each other namely Peak Crush Force (PCF) and energy absorption per unit mass (SEA). In order to fulfill these purposes, Radial Base Function (RBF) and Non-dominated Sorting Genetic Algorithm (NSGA II) are adopted. It was observed that double circular tube containing foam exhibit higher energy absorption than that of an empty double circular tube. As such, this structure could be recommended as a power absorbent component such as a side beam on a vehicle door.
