OPTIMIZATION OF CAR BUMPER

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INTRODUCTION CAR BUMPERS:

Inautomobiles, abumperis the front-most or rear-most part, designed to allow the car to sustain an impact without damage to the vehicle's safety systems. They are not capable of reducing injury to vehicle occupants in highspeed impacts, but are increasingly being designed tomitigate injurytopedestriansstruck by cars. The car bumper is designed to prevent or reduce physical damage to the front and rear ends of passenger motor vehicles in low-speed collisions. In most jurisdictions, bumpers are legally required on all vehicles. The height and placement of bumpers may be legally specified as well, to ensure that when vehicles of different speed are in an accident. Designing the bumper with the focus on an improvement

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This project intention is to design an improved of front car bumper and to find the solution for the problem of high cost and the replacing cost for the front bumper and lastly emphasizing the cost reducing aspect. Different materials can be used in production of car bumpers:
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PVC Plastic-Polycarbonate (Molded) Plastic-Nylon Type 6/6 Plastic ABS (Molded). AISI E 52100 Steel

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PROBLEM IDENTIFICATION

Nowadays the part cost for front bumper is still high and the cost for replacing is quite expensive especially if surrounding area or part also damaged. Many part that make up a bumper system, involving a lot of material and processes there for the manufacturer difficult to reduce the price. Customer also blame to the manufacture that the bumper easily to damage although the 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 front bumper system, design and analyze the alternative front bumper using CAD software. And to achieve the objective of the project, the following activities are performed:
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To analyze on mechanical properties focus on stress analysis. Benchmark the current front car bumper design (MARUTI 800) To modeling the actual dimension of the car bumper into the Solid Work software and analyze between the current design and the alternative design. Perform CAE simulation to the alternative bumper.

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LITERATURE REVIEW
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A good design of car bumper must provide safety for passengers and should have low weight (Marzbanradet al ., 2009). Beside the role of safety, fuel efficiency and emission gas regulations are being more important which encourage manufacturer to reduce the weight of passenger cars (Hosseinzadehet al., 2005). It is not a safety feature intended to prevent or mitigate injury 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 related equipment such as parking lights, headlamps and taillights in low speed collisions (Status Report,Vol 4, No 2, IIHS, 2007).

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Generally, a bumper is attached to either end of a vehicle to absorb impact in a collision, thereby protecting 3/20/13 passenger. As shown in figure 1, a conventional bumper

4. Many researchers have studied the four main variables during crash simulation and analysis (Kim, 2008;Marzbanrad et al., 2009;Hosseinzadehet al., 2005). The first variable studied is the material. It has been exposed in this research as a substitution in order to lower part weights and define whether the material can affect the impact of collision or not. In this section, the effect of modulus of elasticity and yield strength on impact behavior of bumper beam was investigated. Thickness is the second variable that has been studied in order to relate between bumper and thickness that can 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 crash performance 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 impact modelling using Abaqus 6.9 according to the speed that is 13.3 m sec-1(48 km h-1) given in order to analyse the results. This speed is according to regulations of Federal Motor Vehicle Safety Standards, FMVSS 208- Occupant Crash Protection whereby the purpose and scope of this standard specifies requirements to afford impact protection for passengers. the three types of material were selected that are relevant to be applied to the front bumper beam. The materials consist of Expanded Polypropylene (EPP), Glass Mat Thermoplastics (GMT) and Sheet Molding Compound (SMC). These materials were studied by impact modelling to determine the kinetic energy, potential energy and strain energy. The selected materials are compared to each other to find the best material with highest material strength and structure. Simulation using Finite Element Analysis software, which is ABAQUS was conducted. The results 3/20/13 showed that a modified SMC bumper can reduce the impact

REFERENCES
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Marzbanrad, J., M. Alijanpour and M.S. Kiasat, 2009.Design and analysis of automotive bumper beam in low speed frontal crashes. Thin-Walled Struct., 47: 902911. Hosseinzadeh, R., M. Shokrieh and L.B. Lessard, 2005.Parametric study of automotive composite bumper beams subjected to low-velocity impacts. J. Composite Struct., 68: 419-427.

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