CRASHWORTHINESS INVESTIGATION OF VEHICLE FRONT BUMPER BEAM WITH DIFFERENT CROSS-SECTIONS UNDER AXIAL DYNAMIC LOAD

Bumper beam, is one of the first structures exposed to impact at the time of an accident. Therefore, how it behaves at the time of an accident is extremely important in terms of passenger safety, cargo and other critical parts of the vehicle. What is expected from a bumper beam is to absorb the kinetic energy of the vehicle through plastic deformation, particularly at low and medium speeds. In this study, finite element models of the crash situations of the bumper beams with five different cross-sectional geometries and equal weights were created by using the HyperMesh software and crash analyses were carried out. Since the bumper beams may behave differently in different barrier types, pole and wall barrier impact test was investigated. AA6061-T6 Aluminum alloy was used as the material and Johnson-Cook was used as the material model. The results revealed that the cross-sectional geometry had significant effect on crashworthiness and that the models exhibited different crashworthiness on wall and pole barriers. RADIOSS/explicit and non-linear finite element codes were used.

___

  • [1] Sun, G.Y., G.Y. Li, S.W. Zhou, H.Z. Li, S.J. Hou, and Q. Li,(2011) Crashworthiness design of vehicle by using multiobjective robust optimization. Structural and Multidisciplinary Optimization. 44(1): p. 99-110, doi:10.1007/s00158-010-0601-z.
  • [2] Yang, R.J., N. Wang, C.H. Tho, and J.P. Bobineau,(2005) Metamodeling development for vehicle frontal impact simulation. Journal of Mechanical Design. 127(5): p. 1014-1020, doi:10.1115/1.1906264.
  • [3] Jones, N., Structural impact. 2011: Cambridge university press.
  • [4] Cheon, S.S. and J.H. Choi,(1995) Development of the composite bumper beam for passenger cars. Composite Structures. 32(1-4): p. 491-499, doi:10.1016/0263-8223(95)00078-X.
  • [5] HASHIMOTO, N.,(2017) Application of Aluminum Extrusions to Automotive Parts. Kobelco Technology Review, (35): p. 69-75.
  • [6] Safari, H., H. Nahvi, and M. Esfahanian,(2018) Improving automotive crashworthiness using advanced high strength steels. International Journal of Crashworthiness. 23(6): p. 645-659, doi:10.1080/13588265.2017.1389624.
  • [7] Wierzbicki, T. and W. Abramowicz,(1983) On the Crushing Mechanics of Thin-Walled Structures. Journal of Applied Mechanics-Transactions of the Asme. 50(4a): p. 727-734, doi:Doi 10.1115/1.3167137.
  • [8] Khatri, N.A., H. Shaikh, Z.A. Maher, A. Shah, and S.F. Ahmed,(2018) A Review on Optimization of Vehicle Frontal Crashworthiness for Passenger Safety. International Journal of Engineering & Technology. 7(2.34): p. 1-4, doi:10.14419/ijet.v7i2.34.13894.
  • [9] Patil, S.A., R. Moradi, and H.M. Lankarani. Vehicle mass optimization for frontal structure using I-sight and study of weld parameterization for mass improvement. in ASME 2014 International Mechanical Engineering Congress and Exposition. 2014. American Society of Mechanical Engineers.
  • [10] Zhang, Z.H., S.T. Liu, and Z.L. Tang,(2009) Design optimization of cross-sectional configuration of rib-reinforced thin-walled beam. Thin-Walled Structures. 47(8-9): p. 868-878, doi:10.1016/j.tws.2009.02.009.
  • [11] Belingardi, G., A.T. Beyene, E.G. Koricho, and B. Martorana,(2015) Alternative lightweight materials and component manufacturing technologies for vehicle frontal bumper beam. Composite Structures. 120: p. 483-495, doi:10.1016/j.compstruct.2014.10.007.
  • [12] Ding, M., J. Liu, B. Liu, X. Wang, T. Li, and D. Cao. On the development of automotive composite material rear bumper beam. in Proceedings of SAE-China Congress 2015: Selected Papers. 2016. Springer.
  • [13] Wang, G., J. Zhou, Z. Liu, L. Li, B. Liu, X. Li, et al.,(2012) Lightweight design and crash performance analysis of automotive aluminum bumper. The Chinese Journal of Nonferrous Metals. 22(1): p. 90-98.
  • [14] Hosseinzadeh, R., M.M. Shokrieh, and L.B. Lessard,(2005) Parametric study of automotive composite bumper beams subjected to low-velocity impacts. Composite Structures. 68(4): p. 419-427, doi:10.1016/j.compstruct.2004.04.008.
  • [15] Tanlak, N., F.O. Sonmez, and M. Senaltun,(2015) Shape optimization of bumper beams under high-velocity impact loads. Engineering Structures. 95: p. 49-60, doi:10.1016/j.engstruct.2015.03.046.
  • [16] Johnson, G.R.,(1983) A constitutive model and data for materials subjected to large strains, high strain rates, and high temperatures. Proc. 7th Inf. Sympo. Ballistics: p. 541-547.
  • [17] Wang, Q., F. Wu, B. Tang, and C. Li. Damage Behavior of Boron Steels with Various Hardness Using the GTN and the Johnson-Cook Model. in Advanced High Strength Steel And Press Hardening-Proceedings Of The 4th International Conference On Advanced High Strength Steel And Press Hardening (Ichsu2018). 2018. World Scientific.
  • [18] Raman, R., K. Jayanth, I. Sarkar, and K. Ravi. Analyzing the effect of carbon fiber reinforced polymer on the crashworthiness of aluminum square hollow beam for crash box application. in IOP Conference Series: Materials Science and Engineering. 2017. IOP Publishing.
  • [19] Estrada, Q., D. Szwedowicz, A. Rodriguez-Mendez, M. Elías-Espinosa, J. Silva-Aceves, J. Bedolla-Hernández, et al.,(2019) Effect of radial clearance and holes as crush initiators on the crashworthiness performance of bi-tubular profiles. Thin-Walled Structures. 140: p. 43-59, doi:10.1016/j.tws.2019.02.039.
  • [20] Lesuer, D.R., G. Kay, and M. LeBlanc, Modeling large-strain, high-rate deformation in metals. 2001, Lawrence Livermore National Lab., CA (US).
  • [21] Gumruk, R. and S. Karadeniz,(2009) The influences of the residual forming data on the quasi-static axial crash response of a top-hat section. International Journal of Mechanical Sciences. 51(5): p. 350-362, doi:10.1016/j.ijmecsci.2009.03.010.
  • [22] Toksoy, A.K. and M. Guden,(2010) Partial Al foam filling of commercial 1050H14 Al crash boxes: The effect of box column thickness and foam relative density on energy absorption. Thin-Walled Structures. 48(7): p. 482-494, doi:10.1016/j.tws.2010.02.002.
  • [23] Ahmad, Z. and D.P. Thambiratnam,(2009) Dynamic computer simulation and energy absorption of foam-filled conical tubes under axial impact loading. Computers & Structures. 87(3-4): p. 186-197, doi:10.1016/j.compstruc.2008.10.003.
  • [24] Zheng, G., T. Pang, G.Y. Sun, S.Z. Wu, and Q. Li,(2016) Theoretical, numerical, and experimental study on laterally variable thickness (LVT) multi-cell tubes for crashworthiness. International Journal of Mechanical Sciences. 118: p. 283-297, doi:10.1016/j.ijmecsci.2016.09.015.