Bumper Beam Research Articles

Research on Integrated Optimization of Design Parameters and Process Simulation for Throughput Efficiency

This thesis presents a comprehensive approach to enhance the production throughput of aluminium bumper beams, a critical component in automotive manufacturing. Using CATIA, an innovative bumper beam design was developed, focusing on simplicity of design and manufacturability. The design parameters considered included material selection, cross-sectional area optimization, and welding techniques to ensure both performance and ease of manufacturing. Transitioning to Tecnomatix Plant Simulation, a virtual environment was constructed to simulate the bumper beam production process. The simulation incorporated the identified design parameters, process routes, layout considerations, and machine arrangements to optimize throughput without inflating costs. By leveraging advanced simulation techniques, the study aimed to identify the most efficient production strategies while maintaining design integrity and minimizing resource consumption. Through systematic scenarios experimentation and analysis, the research yielded insights into the complex relationship between design decisions and manufacturing processes. The results highlight the potential for significant throughput enhancements achievable through collaborative optimization of design and production parameters. The optimization was able to achieve an increase in throughput of about 12.64% of its initial throughput. Moreover, the study underscores the importance of holistic approaches integrating design engineering with manufacturing simulation to drive continuous improvement in industrial operations. This thesis contributes to advancing automotive manufacturing practices by offering a methodology for enhancing production efficiency while preserving product quality and cost-effectiveness. The findings provide valuable guidance for engineers and practitioners seeking to optimize manufacturing processes through the use of simulation and design parameters

Frontal bumper beam of automobile vehicle analysis by using different materials

Abstract An automotive bumper is a key component designed to protect passengers from front and rear collisions. Bumpers serve a crucial function in absorbing collision forces to protect both the vehicle and its occupants. The ABAQUS/Explicit code is used to investigate the influence of the bumper beam parameters on their impact resistance. Eight materials (4 metallic and 4 composite) were compared to see how material modifications would improve outcomes and determine the optimal bumper beam material. Four bumper designs (profile-A, profile-B, profile-C, and profile-D) were compared to see how design adjustments would improve outcomes and discover the optimum bumper beam configuration.

Strength Analysis of the Front Bumper Beam of a Passenger Car

This article presents a computer simulation carried out in the Solidworks environment, the bumper beam of a passenger car was tested. The simulation took into account the influence of various aluminum alloys and the type of reinforcement in the crosssection of the beam on the strength of the entire element at the time of collision at different forces. The analysis provided answers in which places the accumulation of stresses occurs, and thus the places most exposed to destruction

Finite element analysis regarding folding behaviour of different crashbox versions

Low-speed collision is one of the most frequent road accident types nowadays. The consequences of this accident could be serious and long terminated. The passive safety system has an important role to reduce and prevent the amount of personal and technical injuries. Applying front and rear bumper beams is a good way to absorb more impact energy at the moment of collision reducing the load of the occupants. The background of the energy absorbing is the prescribed folding deformation of the bumper's support namely the crashbox. The main goal of the present study is to evaluate and compare differently shaped crashboxes as a thin-walled structure using finite element analysing to get information for more effective energy absorption taking into consideration of the weight optimization and spce requirements. To be comparable to the folding fluctuation of each specimen the compression test's curves are evaluated with relative standard density. Moreover, the specific energy absorption is also was determined. Based on the values determined by finite element analysis conclusions could be drawn.

Investigative studies on natural fiber reinforced composites for automotive bumper beam applications

The automotive sector wants lighter, recyclable, degradable, and sustainable composite materials. In the last few decades, natural fiber composite has been used in a wide range. The natural plant-based fibers are reinforced into polymeric composite materials, giving significant mechanical properties compared to conventional material. This work selects flax and sisal fibers due to higher strength and Young’s modulus. Mechanical behavior such as tensile, flexural, and impact strength are evaluated. Mechanical behavior results are considered in the simulation to determine the performance of an automotive bumper beam. The tensile strength of the flax composite is 90% higher than that of the sisal composite. Flexural strength is 17% higher in a flax composite, whereas energy absorption is nearly identical in a flax and sisal composite. The flax composite has a maximum 204.9 MPa tensile strength, 157.98 MPa flexural strength, and 45 J energy absorption. The mechanical behavior results are validated with simulation results in the ANSYS workbench for static analysis. The results indicate that the flax fiber reinforced composite with 43:57 of a flax-matrix ratio performs better as it can be used as a structural material. A morphological study shows the uniform distribution of matrix material and fiber orientation.

Fabrication of a prototype of bumper beam by single point incremental forming of laser welded tailored blank and characterization of its quasi-static crushing performance

Fabrication of a prototype of bumper beam by single point incremental forming of laser welded tailored blank and characterization of its quasi-static crushing performance

Analyzing effects of damping materials on automotive bumper beam assembly under different velocity conditions

Automotive bumper beams play a very crucial role in absorbing impact energy during crash collisions and reducing damage from the front or rear ends of the vehicle during low or high-velocity impact. This paper discusses the impact of different energy-absorbing materials introduced between the fascia and the metallic beam. A novel recipe, with combinations ranging from 0% to 50% and 20% to 80% of Polypropylene (PP) with Ethylene vinyl acetate (EVA) and Polypropylene (PP) with Ethylene propylene diene monomer (EPDM), was prepared by weight and comparative study based on their impact strengths was done both experimentally and numerically. The mechanical properties of the polymer blends have been determined under tensile, compressive, and impact testing. Results obtained from numerical simulation analysis lie in reasonable agreement with the experimental findings. The tensile and compression test results show that polymer blend PP/EPDM-50/50 is the best selection as an energy absorber due to its ductility and toughness properties which is evident from experimental testing. The introduction of this blend in front of the metallic strip (bumper beam) has significantly supported the improvement in the energy-absorbing capacity and impact strength.

Energy absorption characteristics of stepped multi-cell columns subjected to transverse loading

Automotive bumper beam is a vital component that shields passenger and vehicle from harm and damage generated by catastrophic collapse. Previous investigations on its bending behavior have largely concentrated on multi-cell tubes with the same length, whereas stepped multi-cell structures have received less attention. In this paper, a novel stepped multi-cell configuration is proposed to improve the energy absorption characteristics of thin-walled structures under transverse loading. The finite element method is employed to analyze the crushing behaviors of the stepped multi-cell tubes. The numerical results reveal that the stepped multi-cell structures (SM2 to SM5) can reduce the initial peak force by 23.44–45.91% while increasing the energy absorption capacity, crush load efficiency, and specific energy absorption by 5.87–29.51, 38.29–139.45, and 5.87–29.51%, respectively, when compared to a conventional square tube (M1). In addition, the effects of wall thickness, section width, load angle, punch radius, and punch shape on the bending behaviors and energy absorption characteristics are examined. The results indicate that these factors have a considerable influence on the deformation features of M1 and SM2, which leads to a significant reduction in their bending energy absorption characteristics. These variables have no influence on the deformation modes of SM3, SM4, and SM5, and they present local indentation deformation with a high energy absorption efficiency. Increasing the number of layers improves the comprehensive performance of stepped multi-cell tubes, with SM5 exhibiting the best energy absorption characteristics under transverse loading.

The Design of a Piecewise-Integrated Composite Bumper Beam with Machine-Learning Algorithms.

In the present study, a piecewise-integrated composite bumper beam for passenger cars is proposed, and the design innovation process for a composite bumper beam regarding a bumper test protocol suggested by the Insurance Institute for Highway Safety is carried out with the help of machine learning models. Several elements in the bumper FE model have been assigned to be references in order to collect training data, which allow the machine learning model to study the method of predicting loading types for each finite element. Two-dimensional and three-dimensional implementations are provided by machine learning models, which determine the stacking sequences of each finite element in the piecewise-integrated composite bumper beam. It was found that the piecewise-integrated composite bumper beam, which is designed by a machine learning model, is more effective for reducing the possibility of structural failure as well as increasing bending strength compared to the conventional composite bumper beam. Moreover, the three-dimensional implementation produces better results compared with results from the two-dimensional implementation since it is preferable to choose loading-type information, which is achieved from surroundings when the target elements are located either at corners or junctions of planes, instead of using information that comes from the identical plane of target elements.

The optimisation design of CFRP bumper beam based on ply compatibility

The optimisation design of CFRP bumper beam based on ply compatibility

The optimisation design of CFRP bumper beam based on ply compatibility

The optimisation design of CFRP bumper beam based on ply compatibility

Investigation Of Stacking Layer Effect on The Kenaf Hybrid Composite Mechanical Properties for Automotive Application

The field of automotive manufacturing continually seeks innovative, sustainable materials with an emphasis on mechanical robustness. The study is aimed at investigating the Kenaf fibers' potential as an alternative to synthetic fiber composites in automotive bumper beams, shedding light on the mechanical properties of this hybrid composite. The primary focus lies on the impact of different fiber orientations: unidirectional, bidirectional, and 45-degree angles. Using the hand layup process, a natural fiber composite served as the material for constructing the sample, tested for mechanical properties with a Universal Testing Machine. Findings from both tensile and flexural tests illuminate the mechanical properties of Kenaf fiber composite, providing valuable insights into its utilization potential. The Kenaf hybrid composite showcased viable mechanical properties, suggesting its potential for automotive applications. The research establishes Kenaf fibers as a promising, sustainable alternative that could revolutionize the automotive industry without compromising structural integrity.

Laser forming of aluminium foam sandwich into a shock-absorbing structural part

The inefficacy of the conventional methods to form Aluminium Foam Sandwich (AFS) has led to the evolution of laser forming as an alternative. However, the current literature lacks studies that demonstrate the capability of the laser forming to form a targeted part out of AFS. The current study for the first time proposed a methodology and revealed salient factors relevant to laser forming an AFS panel into a prescribed scaled-down model (bumper beam). Estimation of the scan line position and the experimental methodology to obtain the desired process parameters against each scan line to obtain the targeted part are demonstrated. Chances of failure of the AFS part during the laser forming were investigated using finite element simulation. The laser-formed part that was finally obtained conformed well to the targeted shape and also exhibited improved flexural strength with no loss of local compressibility under the three-point bending test.

EVALUATION OF MATERIAL SELECTION FOR POLYMERIC COMPOSITE AUTOMOTIVE BUMPER BEAM USING THE WEIGHTED SUM METHOD (WSM)

A bumper beam is the curved bar across the front of an automobile that protects it from getting dented or scratched during minor accidents Polymeric composite automobile bumper beam material choices. The composites used in vehicle bumper beams need to be selected with care since they have a major job in the distribution and absorption of impact forces during collisions. In recent years, bumper beam applications have seen a rise in the usage of polymeric composites because of their rare connection of mechanical properties, low weight& design flexibility. This introductions goal is to provide a broad overview of the selection process for elements for polymeric composite automobile bumper beams. Research on bumper of an automobile is very important because a vehicles bumper is designed to absorb as much impact as possible, protecting the more important parts of the vehicle. Inthisstudy,theweightedsummethod(WSM)isusedtofindsuitablecompositepolymermaterialsforautomotivebumperbeams. Six different materials are tested in order to choose It is the absolute material for polymer composite bumper beams in transport. The final rank of this paper the Glass fibre reinforced epoxy (M−1) in 1strank, the Carbon fibre reinforced epoxy (M−2) is in 2nd rank, the Carbon fibre reinforced polypropylene (10%) (M−3) is in 6th rank, the Glass fibre reinforced polypropylene (40%) (M−4) is in 3rd rank, the Glass fibre reinforced polyester (30%) (M−5) in 5th rank, the Glass fibre vinyl ester SMC (60%) (M−6) in 4th rank. The final result is done by using the WSM method. For the material selection of automotive bumper beam,the final rank of this paper the Glass fibre reinforced epoxy (M−1) in 1strank,the Carbon fibre reinforced epoxy (M−2) is in 2nd rank, the Carbon fibre reinforced polypropylene (10%) (M−3) is in 6th rank, the Glass fibre reinforced polypropylene (40%) (M−4) is in 3rd rank, the Glass fibre reinforced polyester (30%) (M−5) in 5th rank, the Glass fibre vinyl ester SMC (60%) (M−6) in 4th rank. The final result is done by using the WSM method.

Transition from earth mining toward urban mining: up-cycling post-consumer scraps to produce automotive grade aluminum extrusions

Aluminum extrusions encompass a range of structural components for managing crash energy. Currently automotive grade aluminum extrusions are made from primary aluminum of high carbon footprint. This study proposes a pathway to significantly reduce carbon footprint of automotive grade aluminum extrusions via using post-consumer scrap. Guided by thermodynamics-based simulations, 0.25 wt% was set as the iron tolerance limit for aluminum AA6082 alloy extrusion. This enables a scrap utilization ratio exceeding 70% in casting, which has been demonstrated in a production trial. Extrusions made from the low-carbon AA6082 alloy has a yield strength of 316.3 ± 3.5 MPa, an ultimate tensile strength of 343.9 ± 1.9 MPa, and a tensile elongation of 13.4 ± 1.2%, all of which are comparable to those of the commercial AA6082 extrusion made from 100% primary aluminum. Component-level 3-point bending test shows that front bumper beams made from low-carbon and commercial AA6082 alloys have the same performance. These results indicate that up-cycling post-consumer aluminum scrap to produce automotive grade extrusions is a promising route to help decarbonize vehicle manufacturing process.

Optimization of the crashworthiness design of carbon fiber-reinforced polymer bumper beam

To improve the safety performance and light weight of the bumper subsystem under low-speed collisions with multiple loads, this study develops a systematic optimization strategy. First, the accuracy of the finite element model is verified through experiments. Meanwhile, the crashworthiness of the three different bumper beams made of aluminum alloy, high-strength steel, and carbon fiber-reinforced polymer (CFRP) is compared and analyzed. Second, the optimal combination of single-layer thickness and lay-up angle of the CFRP bumper beam is discussed. Finally, an optimization strategy combining Hammersley experimental design, hybrid approximation model, NSGA-II algorithm, combined weights, and technique for order preference by similarity to an ideal solution and grey relational analysis (TOPSIS&GRA) integrated decision is proposed and applied to the optimal design of the CFRP bumper beam. The optimization results show that the optimized CFRP bumper beam is 57.18% lighter than the original aluminum composite bumper beam while meeting the requirements of crashworthiness.

Load distribution structure of rear bumper beam to enhance vehicle body energy absorption in rear-end collisions

Objective This research focused on FMVSS301, which is required for higher energy absorption as a regulation for rear-end collisions. Since they are offset collisions, the deformation of the non-collision side frame, which does not directly contact the barrier, is less than on the collision side. The reason is that the rear bumper beam with curvature is deformed into a straight shape by the load from the barrier, resulting in an asymmetrical load distribution from the barrier that is biased toward the collision side. Therefore, the objective of this research was to construct a new bumper beam structure that reduces the difference in the load input to both frames and increases the energy absorption of the non-collision side frame. Method The basic principle is to generate a counterforce against the lateral loads during transmitting the load from barrier to the frames. To achieve this, a bow-shaped rear bumper beam structure was devised. The rear bumper beam corresponds to the bow and the newly added connection plate to the string. The lateral load increase is suppressed and load distribution to the rear frame is maintained. Results The designed rear bumper beam and rear components equipped with the rear bumper beam were both prepared and evaluated by drop test. With testing of the rear bumper beam, it was demonstrated that the load in the lateral direction, which conventionally generates over 80 kN, could be canceled. Tests of the rear component demonstrated that load distribution to the rear frame could be maintained, and the energy absorption of the non-collision side frame could be enhanced by 35 times. The total energy absorption of the barrier and the two frames was demonstrated to increase 2.9 times. Conclusion The bow-shaped rear bumper beam was designed to distribute the load evenly to the collision and non-collision side frames, and to deform both frames, thereby achieving a higher energy absorption of the entire vehicle body. This is expected to be applicable to electric vehicles and FCVs, which require more energy absorption with increased vehicle weight.

Design and optimization of the bumper beam with corrugated core structure of fiber metal laminate subjected to low-velocity impact

Fiber metal laminates (FMLs) exhibit good impact resistance performance with hybrid structures based on alternating stacking of metal alloy layers and fiber-reinforced composite plies. Therefore, FMLs become excellent candidates for bumper beams in automobiles with an enhanced energy absorption capacity. Herein, the design and optimization of the bumper beam consisted of FMLs corrugated sandwich structure subjected to low-velocity impact were investigated. Firstly, material characteristic parameters of aluminum alloy and carbon fiber reinforced thermoset polymer (CFRP) were obtained from the quasi-static and dynamic experiments respectively. Then, finite element analysis (FEA) of cap structures of FMLs was established to capture the deformation process of the low-velocity impact. The simulation results were well-validated using material parameters from the dynamic mechanical tests. Afterward, the influence of material type and stacking sequences on performance was numerically investigated under low-velocity impact loading, whereas the performance of aluminum alloy and CFRP were set as controls. A multi-objective optimization method was considered to realize the maximum energy absorption with minimum impact peak force. The non-dominated sorting genetic algorithm II (NSGA-II) was introduced to obtain the global optimum solution. The current work highlights the excellent mechanical performance of the FMLs bumper beam in low-velocity impact.

Composite Plastic Hybrid for Automotive Front Bumper Beam

The bumper beam is a crucial component of the automobile bumper system, responsible for absorbing impact energy and enhancing the safety of passengers during collisions. This paper presents the design and experimental analysis of a 3D-printed composite–plastic hybrid light structure, designed as a collapsible energy absorber. Exploratory testing was conducted using low-impact tests to investigate the failure mechanism and energy absorption capacity of a spiral structure. The design process involved optimizing the spiral diameter by testing specimens with varying diameters between 0.5 cm and 2.5 cm, while keeping other geometric parameters constant. The study employed three types of 3D composite structures, including printed thermoplastic, printed thermoplastic reinforced with Kevlar fiber composite, and printed thermoplastic filled with foam. The thermoplastic–foam composite with nine spirals (diameter = 0.97 cm) yielded the best results. The new design demonstrated high energy absorption capacity and a controlled and progressive failure mechanism, making it a suitable candidate for energy absorption applications.

Using machine learning prediction models for quality control: a case study from the automotive industry

This paper studies a prediction problem using time series data and machine learning algorithms. The case study is related to the quality control of bumper beams in the automotive industry. These parts are milled during the production process, and the locations of the milled holes are subject to strict tolerance limits. Machine learning models are used to predict the location of milled holes in the next beam. By doing so, tolerance violations are detected at an early stage, and the production flow can be improved. A standard neural network, a long short term memory network (LSTM), and random forest algorithms are implemented and trained with historical data, including a time series of previous product measurements. Experiments indicate that all models have similar predictive capabilities with a slight dominance for the LSTM and random forest. The results show that some holes can be predicted with good quality, and the predictions can be used to improve the quality control process. However, other holes show poor results and support the claim that real data problems are challenged by inappropriate information or a lack of relevant information.