Design and Analysis of Automotive Bumper Covers in Transient Loading Conditions

Abstract:

This paper presents the analysis methods for design of automotive bumper covers. The bumper covers are plastic structures attached to the front and rear ends of an automobile and are expected to absorb energy in a minor collision. One requirement in design of the bumper covers is to minimize the bumper deflection within a limited range under specific loadings at specific locations based on the design guideline. To investigate the stiffness performance under various loading conditions, a numerical model based on the explicit dynamic finite element analysis (FEA) using the commercial FEA solver, LS-DYNA, is developed to analyze the design. The experimental tests are also carried out to verify the numerical model. The thickness of the bumper cover is a design variable which usually varies from 3 to 4 mm depending on locations. To improve the stiffness of the bumper, an optimal design for the bumper under a pre-defined loading condition is identified by using the topology optimization approach, which is an optimal design method to obtain the optimal layout of an initial design domain under specific boundary conditions. The outcome of this study provides an efficient and cost-effective method to predict and improve the design of automotive bumper covers.

• Periodical: Key Engineering Materials (Volume 715)
• Pages: 174-179
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.715.174
• Online since: September 2016
• Authors: Chih Hsing Liu*, Ying Chia Huang, Chen Hua Chiu, Yu Cheng Lai, Tzu Yang Pai
• Keywords: Bumper, Contact Analysis, Finite Element Analysis, Topology Optimization

References

[1] Y. Matsui, Effects of vehicle bumper height and impact velocity on type of lower extremity injury in vehicle–pedestrian accidents, Accident Analysis & Prevention, 37: 4 (2005) 633-640.

DOI: 10.1016/j.aap.2005.03.005

[2] Y. Matsui, M. Hitosugi, K. Mizuno, Severity of vehicle bumper location in vehicle-to-pedestrian impact accidents, Forensic Science International, 212: 1–3 (2011) 205-209.

DOI: 10.1016/j.forsciint.2011.06.012

[3] E.M. Ossiander, T.D. Koepsell, B. McKnight, Will the light truck bumper height-matching standard reduce deaths in cars?, Accident Analysis & Prevention, 51 (2013) 292-300.

DOI: 10.1016/j.aap.2012.12.004

[4] M.M. Davoodi, S.M. Sapuan, A. Aidy, N.A. Abu Osman, A.A. Oshkour, W.A.B. Wan Abas, Development process of new bumper beam for passenger car: A review, Materials & Design, 40 (2012) 304-313.

DOI: 10.1016/j.matdes.2012.03.060

[5] G. Belingardi, A.T. Beyene, E.G. Koricho, B. Martorana, Alternative lightweight materials and component manufacturing technologies for vehicle frontal bumper beam, Composite Structures, 120 (2015) 483-495.

DOI: 10.1016/j.compstruct.2014.10.007

[6] D. -H. Kim, H. -G. Kim, H. -S. Kim, Design optimization and manufacture of hybrid glass/carbon fiber reinforced composite bumper beam for automobile vehicle, Composite Structures, 131 (2015) 742-752.

DOI: 10.1016/j.compstruct.2015.06.028

[7] Z.Q. Cheng, J.G. Thacker, W.D. Pilkey, W.T. Hollowell, S.W. Reagan, E.M. Sieveka, Experiences in reverse-engineering of a finite element automobile crash model, Finite Elements in Analysis and Design, 37: 11 (2001) 843-860.

DOI: 10.1016/s0168-874x(01)00071-3

[8] G.R. Consolazio, J.H. Chung, K.R. Gurley, Impact simulation and full scale crash testing of a low profile concrete work zone barrier, Computers & Structures, 81: 13 (2003) 1359-1374.

DOI: 10.1016/s0045-7949(03)00058-0

[9] L. Kwasniewski, C. Bojanowski, J. Siervogel, J.W. Wekezer, K. Cichocki, Crash and safety assessment program for paratransit buses, International Journal of Impact Engineering, 36: 2 (2009) 235-242.

DOI: 10.1016/j.ijimpeng.2008.05.003

[10] N. Li, H. Fang, C. Zhang, M. Gutowski, E. Palta, Q. Wang, A numerical study of occupant responses and injuries in vehicular crashes into roadside barriers based on finite element simulations, Advances in Engineering Software, 90 (2015) 22-40.

DOI: 10.1016/j.advengsoft.2015.06.004

[11] C. -H. Liu, and K. -M. Lee, Dynamic modeling of damping effects in highly damped compliant fingers for applications involving contacts, ASME Journal of Dynamic Systems, Measurement and Control, 134 (2012) 011005-1-9.

DOI: 10.1115/1.4005270

[12] K. -M. Lee, C. -H. Liu, Explicit dynamic finite element analysis of an automated grasping process using highly damped compliant fingers, Computers and Mathematics with Applications, 64: 5 (2012) 965-977.

DOI: 10.1016/j.camwa.2012.02.033

[13] C. -H. Liu, W. Chen, W. Su, C. -N. Sun, Numerical and experimental analysis of the automated demolding process for PDMS microfluidic devices with high-aspect ratio micropillars, International Journal of Advanced Manufacturing Technology, 80: 1 (2015).

DOI: 10.1007/s00170-015-6959-8

[14] R.R. Magalhaes, C.H.O. Fontes, S.A.B. Vieira de Melo, Stress analysis of a front bumper fascia using the boundary element method, Engineering Analysis with Boundary Elements, 36: 8 (2012) 1296-1300.

DOI: 10.1016/j.enganabound.2012.02.008

[15] H.A. Eschenauer, N. Olhoff, Topology optimization of continuum structures: a review, ASME Applied Mechanics Reviews, 54: 4 (2001) 331-390.

DOI: 10.1115/1.1388075

[16] G.I.N. Rozvany, Stress ratio and compliance based methods in topology optimization - a critical review, Structural and Multidisciplinary Optimization, 21: 2 (2001) 109-119.

DOI: 10.1007/s001580050175

[17] G.I.N. Rozvany, A critical review of established methods of structural topology optimization, Structural and Multidisciplinary Optimization, 37: 3 (2009) 217-237.

DOI: 10.1007/s00158-007-0217-0

[18] O. Sigmund, K. Maute, Topology optimization approaches, Structural and Multidisciplinary Optimization, 48(6) (2013) 1031-1055.

DOI: 10.1007/s00158-013-0978-6

[19] C. -H. Liu, G. -F. Huang, A topology optimization method with constant volume fraction during iterations for design of compliant mechanisms, ASME Journal of Mechanisms and Robotics, 8: 4 (2016) 044505-1-7.

DOI: 10.1115/1.4032812

[20] M. Cavazzuti, A. Baldini, E. Bertocchi, D. Costi, E. Torricelli, P. Moruzzi, High performance automotive chassis design: a topology optimization based approach, Structural and Multidisciplinary Optimization, 44: 1 (2011), 45-56.

DOI: 10.1007/s00158-010-0578-7

[21] C. Li, I.Y. Kim, J. Jeswiet, Conceptual and detailed design of an automotive engine cradle by using topology, shape, and size optimization, Structural and Multidisciplinary Optimization, 51: 2 (2015) 547-564.

DOI: 10.1007/s00158-014-1151-6