During the conceptualization of vehicle, it is big challenge for automotive manufacturer to design a vehicle which has an excellent aesthetic looks as well as meet the stringent vehicle regulations. In the vehicle styling, bumper plays an important role in deciding of the contemporary looks of the vehicle. To improve customer satisfaction, it is important to design a bumper which provides feeling and sense of durability.
In addition, bumper should sustain low-speed impact and protects the peripheral components such as parking lights, headlamps, hood, back door and safety related installed equipments like Rear parking camera, parking sensors, etc. Bumper should be dent resistant and be able to regain its original shape on removal of the applied load. An elegant design of bumper should be light weight with high strength.
This paper explains about a new CAE methodology developed to simulate the real life loading condition of bumper and to calculate the deformation in the bumper. Physical testing is being conducted to validate the design. On the basis of CAE and test correlation results, an optimized design of bumper is developed which not only meets the vehicle regulations but also saves significant weight and cost.