Development of Unidirectional CFRP Reinforced Aluminum Bumper Reinforcement

Since bumper reinforcements are positioned at front/rear ends of vehicles, weight reduction of the bumper reinforcements enhances vehicle dynamic performance by reducing a yaw moment of inertia. CFRP (Carbon Fiber Reinforced Plastic) composites are attractive lightweight materials due to their excellent specific strength and rigidity. However, because of their relatively high cost, applications of CFRP materials to vehicle structural parts are limited. In this study we have developed a lightweight, structural part, which consists of a thin-walled Al (Aluminum) bumper reinforcement with a UD (Unidirectional)-CFRP sheet. The intention is to prevent an increased part cost by reducing the amount of Al and by minimizing the amount of CFRP. Compared to Al, UD-CFRP sheets have even higher tensile strength and modulus. When vehicles crash, bumper reinforcements may be subjected to bending force. If a UD-CFRP sheet is adhered on the tensile side of an Al bumper reinforcement, not only Al thickness on the tensile side, but also thickness on the compression side can be reduced due to movement of the bending neutral axis. In this design with a multi-material structure, bending strength of the developed part can’t be predicted by a full plastic moment which could normally be used to predict metal parts’ bending strength under large deformation. We employed a novel cross-section design method which can be used to predict bending strength of CFRP reinforced metal structures under large deformation. To validate the calculation method, three-point bending tests on the parts were carried out. Experimental data of bending strength were in the range of predicted bounds. Also, in order to launch the developed part, robustness of part’s performance was evaluated. Finally, the part was adapted to the rear bumper reinforcement of LEXUS RC-F. The part weight is 11 % lighter compared to the conventional, all-Al, bumper reinforcement.