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Automotive bumper according to IIHS
& RCAR
Low speed collisions are common in areas with traffic congestion and parking occasions. These collisions
burden 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 the
levels of protection of the vehicle chassis. Careful and appropriate design should be considered in order to
achieve 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 and
the 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 full
frontal 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 bumper
geometry and the simulation analysis was accomplished for materials that are quite common or will be the
state of the art in the near future, like specific aluminum alloys, strengthened thermoplastics and
composite materials. Comparisons in terms of weight and impact performance were made. The bumpers
geometry was invariable and the effect of interior additions, like horizontal / vertical composite absorbers
or polystyrene foam, on the bumpers deformation was studied, in order to assess the crashworthiness of
each configuration.
The contribution of the advanced Applied Mechanics Laboratory to FEAC, by providing knowledge and
technology 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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FEAC - Ansys Hall of Fame Award 2014
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