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Automotive bumper according to IIHS& RCARLow speed collisions are common in areas with traffic congestion and parking occasions. These collisionsburden economically the car owners and could have been avoided with suitable design of car bumpers.Bumper beams are one of the most important structures in passenger cars, relative to the safety and thelevels of protection of the vehicle chassis. Careful and appropriate design should be considered in order toachieve best impact behavior.

There is no beaten track regarding the bumper beam design, neither its geometry nor the materials used.

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Consequently, there is a wide range of design and manufacturing philosophies used in modern cars andthe research and development in this field is enormous and continuous.

The scope of this project was to design and simulate a light weight automotive bumper according to the fullfrontal low-speed impact test established by the IIHS (Insurance Institute for Highway Safety) & the RCAR(Research Council for Automobile Repairs). The design includes a prototypal and innovative bumpergeometry and the simulation analysis was accomplished for materials that are quite common or will be thestate of the art in the near future, like specific aluminum alloys, strengthened thermoplastics andcomposite materials. Comparisons in terms of weight and impact performance were made. The bumper’sgeometry was invariable and the effect of interior additions, like horizontal / vertical composite absorbersor polystyrene foam, on the bumper’s deformation was studied, in order to assess the crashworthiness ofeach configuration.

The contribution of the advanced Applied Mechanics Laboratory to FEAC, by providing knowledge andtechnology transfer has been a key factor for the accomplishment of this project, which included:

Parametric CAD modeling, drafting & parameters documentation

APDL input files & macros

Setup of the parametric explicit FE analysis

Optimization of the structure to better fulfill the standards

Procedure & results documentation

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Physics Involved

Structural analysis

Composite materials

Optimization

Tools Used

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Tools Used

Catia V5

MSC Nastran/Patran

Ansys Classic

APDL Input Files & Macros

ETA VPG

LS-DYNA

LS-Prepost

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