optimization of car bumper

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OPTIMIZATION OF CARBUMPER


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INTRODUCTION

CAR BUMPERS:

In automobiles, a bumper is the front-most or rear-mostpart, designed to allow the car to sustain an impact withoutdamage to the vehicle's safety systems. They are not

capable of reducing injury to vehicle occupants in high-speed impacts, but are increasingly being designedto mitigate injury to pedestrians struck by cars.

The car bumper is designed to prevent or reduce physicaldamage to the front and rear ends of passenger motorvehicles in low-speed collisions.

In most jurisdictions, bumpers are legally required on allvehicles. The height and placement of bumpers may belegally specified as well, to ensure that when vehicles of

different speed are in an accident. Desi nin the bum er with the focus on an im rovement


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This project intention is to design an improved of front carbumper and to find the solution for the problem of high costand the replacing cost for the front bumper and lastly

emphasizing the cost reducing aspect.

Different materials can be used in production of carbumpers:

1. PVC

2. Plastic-Polycarbonate (Molded)

3. Plastic-Nylon Type 6/6

4. Plastic ABS (Molded).

5. AISI E 52100 Steel


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PROBLEM IDENTIFICATION

Nowadays the part cost for front bumper is still high andthe cost for replacing is quite expensive especially ifsurrounding area or part also damaged.

Many part that make up a bumper system, involving a lot

of material and processes there for the manufacturerdifficult to reduce the price. Customer also blame to themanufacture that the bumper easily to damage althoughthe collision was slow.

The material of the bumper should be analyzed to find the

alternative material that can improve the toughness.


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OBJECTIVE

The method have been employed was study the frontbumper system, design and analyze the alternative frontbumper using CAD software. And to achieve the objectiveof the project, the following activities are performed:

1. To analyze on mechanical properties focus on stressanalysis.

2. Benchmark the current front car bumper design(MARUTI 800)

3. To modeling the actual dimension of the car bumperinto the Solid Work software and analyze between thecurrent design and the alternative design.

4. Perform CAE simulation to the alternative bumper.
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LITERATURE REVIEW

1. A good design of car bumper must provide safety forpassengers and should have low weight (Marzbanradet al., 2009). Beside the role of safety, fuel efficiency andemission gas regulations are being more important whichencourage manufacturer to reduce the weight of

passenger cars (Hosseinzadehet al., 2005).

2. It is not a safety feature intended to prevent or mitigateinjury severity to occupants in the passenger cars.Bumpers are designed to protect the hood, trunk, grille,fuel, exhaust and cooling system as well as safety relatedequipment such as parking lights, headlamps and taillightsin low speed collisions (Status Report,Vol 4, No 2, IIHS,2007).

3. Generally, a bumper is attached to either end of a vehicle

to absorb impact in a collision, thereby protectingpassenger. As shown in figure 1, a conventional bumper
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4. Many researchers have studied the four main variablesduring crash simulation and analysis (Kim, 2008; Marzbanradet al., 2009;Hosseinzadehet al., 2005). The first variable

studied is the material. It has been exposed in this research asa substitution in order to lower part weights and definewhether the material can affect the impact of collision or not.In this section, the effect of modulus of elasticity and yieldstrength on impact behavior of bumper beam was

investigated. Thickness is the second variable that has beenstudied in order to relate between bumper and thickness thatcan affect the impact of collision.

5.Bumper design has focused on material and structure.Andersson et al. (2002) investigated the applicability of

stainless steel for crash-absorbing bumpers to increase crashperformance in automotive vehicles.
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METHODOLOGY

Automotive bumper System .Photo courtesy:Neoplen ,2006


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The simulation of a bumper is characterized by impactmodelling using Abaqus 6.9 according to the speed that is13.3 m sec-1 (48 km h-1) given in order to analyse the

results. This speed is according to regulations of FederalMotor Vehicle Safety Standards, FMVSS 208- OccupantCrash Protection whereby the purpose and scope of thisstandard specifies requirements to afford impact protectionfor passengers.

the three types of material were selected that are relevantto be applied to the front bumper beam. The materialsconsist of Expanded Polypropylene (EPP), Glass Mat

Thermoplastics (GMT) and Sheet Molding Compound(SMC).

These materials were studied by impact modelling todetermine the kinetic energy, potential energy and strainenergy. The selected materials are compared to each otherto find the best material with highest material strength andstructure. Simulation using Finite Element Analysis

software, which is ABAQUS was conducted. The resultsshowed that a modified SMC bumper can reduce the impact


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REFERENCES

1. Marzbanrad, J., M. Alijanpour and M.S. Kiasat,2009. Design and analysis of automotive bumper beam inlow speed frontal crashes. Thin-Walled Struct., 47: 902-911.

2. Hosseinzadeh, R., M. Shokrieh and L.B. Lessard,2005. Parametric study of automotive composite bumperbeams subjected to low-velocity impacts. J. CompositeStruct., 68: 419-427.

optimization of car bumper

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