Design Optimization of Passenger Car Front Bumper

Increasing demand to the comfortable cars in low cost make the car makers try to reduce cost for potential components in a car. The dynamic crash sequence of vehicle is progressive in nature. The initial contactor (Bumper or Side Beam) deforms first, then the next structural component and the following component until the energy is absorbed. The initial contactors must be designed to withstand the anticipated crush loads for the various defined impact speeds from defined impact directions. The Insurance companies will evaluate the vehicle performance on frontal crash into a full width fixed barrier as most of the accidents occur due to frontal crash. The main purpose of bumper is to absorb shock in case of a collision. Several materials have been used to develop these shock-absorbing capabilities, such as steel, aluminum, glass mat thermoplastics and sheet molding compound. The purpose of this paper is to design a bumper which is to improve crashworthiness of the bumper beam. Crashworthiness is the ability of the bumper beam to prevent occupant injuries in the event of an accident and this is achieved by minimizing the impact force during the collision. This study was investigated the difference of producing bumper beam using roll forming method compare to stamping method. Based on observations design improvements will be made in terms of shape, size and or material based on design modification objectives. The study was focused on existing design performance, advantage and limitations. Modified front bumper design will be tested using FEM software for impact loads as per international standards.