Evaluation of a Solitary Front Bumper Design for a Midsize Vehicle

Finite-element analyses were used to develop an injection-molded one-piece bumper system for the front bumper of a midsize vehicle (1350 to 1450 Kg). The method used in design was to first examine the performance using linear equations related to four-point bending of abeam. Using results from the initial calculations, a design to fit in a generalized package space was developed and then analyzed for structural integrity in barrier impacts. Results from detailed finite-element analyses were used in further design iterations, and a final design concept was analyzed in all required bumper impacts, excluding corner.

It will be shown that based on package space, deflection requirements, and rail load requirements, an injection-molded one-piece bumper system such as the one presented here should offer acceptable performance while reducing weight and number of parts.