Optimal Design and Experimental Investigations of Aluminium Extrusion Profiles for Lightweight of Car Bumper

Abstract

The present study aimed at developing an aluminium car bumper unit to replace the steel ones by using optimization based on experimental and FEM simulation results. The topology optimization method and response surface methodology (RSM) were applied in order to achieve an optimized design for the cross section of the crossbeam and the crash box, respectively. The three-points bending test and crash test for bumper unit were simulated to evaluate the optimization processes. The 6061 and 6063 aluminium alloy bumper unit has a weight reduction of 67% compared to the steel ones. The new extrusion dies were manufactured to produce profiles for the crossbeam and the crash box, respectively. Then the optimized extrusion profiles of crossbeam and crash box were verified by experimental studies. The performance tests were arranged to validate the experimental product. The mechanical properties of extruded aluminium crossbeam and crash box can satisfy the design requirements of products. The results indicate that the new designed unit can change the whole design of automotive parts for crash energy absorption, and definitely contribute to drastic weight reduction of steel parts.