IIHS introduced new bumper testing program to mimic the kind of low-speed impacts that occur in the real world in 2006. New bumper design is required to meet new bumper testing program that can mimic under-ride or over-ride happening.
This paper is about new bumper design development with optimization and crash analysis.
To reduce computational calculation time, simplified FE model is suggested. Topology optimization is used to find optimum shape of reinforcement bracket which is located at the front of the front back beam rail. DOE(Design of Experiment) method is also used to decide proper dimensions of the bracket. From the DOE results, most effective design variable can be identified. Finally, approximation, RSM(Response Surface Method), is done to get optimum dimension value.
Intrusion, Back Beam Deflection and Back beam height variation during crash are compared between current design and optimum design to identify improvement. Finally, estimated repair costs are compared between current design and optimum design