Design Analysis of Bumper Support Beam

Abstract

Provision of safer vehicles with high fuel efficiency at competitive prices is a prime challenge for the automotive industry. In providing safety, bumper of the car plays a crucial role. It tolerates high velocity impacts. “Crash-Worthiness” is the vehicle response to impact force; less damage means good “Crash-Worthiness”. Bumper beam generally defends vehicle vital parts from damage. Commercial front bumper beam of one of the best-selling cars in Pakistan is studied in this thesis. Efforts were taken to model the bumper beam precisely closer to the reality. Bumper Beam material, mild steel, was identified by Energy-dispersive X-ray spectroscopy (EDX) technique and mechanical testing. The barrier and bumper beam was designed and analyzed using RCAR standards. Front bumper beam test according to the RCAR standards were performed and the bumper beam completely fractured and hence failed the impact test. The bumper beam then optimized using the surface optimization. Radius of curve in the beam and thickness of the beam were our input design parameters. Experimental analysis was performed with 9 design points of radius and thickness. The results were inspected on the basics of total deformation, von Misses stress and directional deformation and energy absorbed. The optimum design presented in this paper shows significant improvement over the one in use and meets all the requirements of the RCAR front test.