Design and analysis of an automotive bumper beam in low-speed frontal crashes

Abstract

In this paper, the most important parameters including material, thickness, shape and impact condition are studied for design and analysis of an automotive front bumper beam to improve the crashworthiness design in low-velocity impact. The simulation of original bumper under condition impact is according to the low-speed standard of automotives stated in E.C.E. United Nations Agreement, Regulation no. 42, 1994. The bumper beam analysis is accomplished for composite and aluminum material to compare the weight and impact behavior. The strength in elastic mode is investigated with energy absorption and impact force in maximum deflection situation. A good design of this part of automotives must prepare for the safety of passengers; meanwhile, should have low weight. Beside the role of safety, fuel efficiency and emission gas regulations are being more important in recent years that encourage manufacturer to reduce the weight of passenger cars. In this research, a front bumper beam made of three materials: aluminum, glass mat thermoplastic (GMT) and high-strength sheet molding compound (SMC) is studied by impact modelling to determine the deflection, impact force, stress distribution and energy-absorption behavior. The mentioned characteristics are compared to each other to find best choice of material, shape and thickness. The results show that a modified SMC bumper beam can minimize the bumper beam deflection, impact force and stress distribution and also maximize the elastic strain energy. In addition, the effect of passengers in the impact behavior is examined. The time history of the calculated parameters is showed in graphs for comparison. Furthermore, beside the above-mentioned benefits, some more advantages like easy manufacturing due to simple shape without-ribs, economical aspects by utilizing low-cost composite material and reducing weight with respect to others can be achieved by SMC material.