Conversion of Aluminum Front Bumper System to Magnesium Material by Using Design of Experiment Method

Abstract

Bumper and crash boxes are vehicle structural elements that convert the collision (kinetic) energy at the collision into deformation energy. Failure of the bumper system to sufficiently absorb the collision energy in the event of a collision will result in the resulting forces being transferred directly to the driver and passenger area. It will result in deaths or injuries to people in the vehicle and further damage to the vehicle. In this study, the collision performance of an existing aluminum crash bumper system produced by the extrusion method with a 40% offset collision analysis is examined. A magnesium crash bumper with improved collision performance is designed by this reference. In this design process, the design of experiment method is used. With the combinations created with the Taguchi method, the long design and analysis process is completed in a shorter time. Taguchi experiment design process; four different design variables and three-level combinations of these variables are used. With the table's help created at the L9 level, models corresponding to the variables are prepared, crash analyzes are performed with finite element analysis, and crash performances are examined. After revealing the results, optimization is carried out with Minitab software; the optimum design is achieved in crash performance and lightness.