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Comparison of Analysis Results to Physical Testing for the Performance of Engineering Thermoplastic Bumper Beams
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Abstract
Engineering thermoplastics are commonly used in the automotive industry as a replacement for steel bumper systems. As the usage of thermoplastics expands in this and other applications, it becomes increasingly desirable to be able to perform preliminary feasibility studies that estimate the performance of the plastic part before tooling is cut. Hence, a study was conducted by GE Plastics in order to correlate the predicted performance of thermoplastic bumper designs via hand calculations and detailed finite-element analyses with results of physical testing. Actual injection-molded thermoplastic bumper beams of a Polycarbonate-Polybutylene Terephthalate alloy were used.
This paper will describe the steps used in bumper design, beginning with hand calculations and detailed finite-element analysis, compare the results obtained to actual physical testing, and make recommendations on techniques for use in future feasibility studies of thermoplastic bumper systems.
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Authors
Citation
Rawson, J., "Comparison of Analysis Results to Physical Testing for the Performance of Engineering Thermoplastic Bumper Beams," SAE Technical Paper 940168, 1994, https://doi.org/10.4271/940168.Also In
References
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- Nimmer, R. P. “First Interim Report - Plastic Bumper Development Program,” General Electric Company, Corporate Research & Development TIS Report No. 82CRD272 October 1982
- Stokes, V.K Nied, H.F. “Solid Phase Sheet Forming of Thermoplastics - Part I: Mechanical Behavior of Thermoplastics to Yield,” Journal of Engineering Materials and Technology April 1986 108 107 112
- ADINA® ADINA Engineering, Inc. 71 Elton Avenue, Watertown, MA, 02172
- Hibbit, Karlsson, Sorenson ABAQUS®/Explicit User's Manual 1992