Design Exploration of Bumper Systems Using Advanced CAE Techniques

This paper describes the development of a design process tool, to explore the design of a bumper system, using advanced CAE techniques. It describes the utility of this tool to identify the main effects and interactions between various parameters of a bumper system on the functional objectives of the bumper system.

Three case studies are presented to demonstrate the capabilities of the tool. In each case study, the critical parameters, affecting the performance criteria, were identified, parameterized, and given suitable ranges. A Finite Element Model morphing program (Morpher) was used to parameterize the finite element models. A design optimization and process integration software package was used to create DOE matrix and again the Morpher was used to generate rapid designs. The analysis was done in an explicit finite element analysis code. The data was post processed using the design optimization software and others.