Abstract
This paper presents a novel approach to design an efficient energy absorber using thermoplastic (PC/PBT Polycarbonate/ Polybutylene Terephthalate) material. Automotive industry always demands minimum package space between bumper beam and fascia from styling perspective. This requires an efficient energy absorber, which can meet the energy absorption target through an idealized force-intrusion performance. In the present study, thermoplastic energy absorber with sequential failure is designed through geometrical configuration to achieve the idealized Force-Deformation (FD) curve. CAE techniques are used extensively for optimizing the design parameters of energy absorber to achieve the desired performance level. The results in the form of FD curve are compared with the idealized curve and the efficiency is calculated. Comparative studies are also performed with foam energy absorber solution. Novel thermoplastic (PC/PBT) energy absorber design achieves high initial stiffness to reach desired force and subsequently maintain the force value. Design shows high-energy absorption efficiencies with the benefit of tuning the stiffness to reach required FD performance through controlled crushing of EA (Energy Absorber). Thus, the necessary packaging space remains minimal through efficient design/material performance.
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