Bumper System Development to Improve Compatibility per Proposed IIHS Bumper Barrier Criteria
Dhiraj Uikey, Darin A. Evans, Ragav Vasudevan
This paper describes a proposed process to design and develop automotive bumper systems to meet the new bumper barrier criteria proposed by the Insurance Institute for Highway Safety (IIHS). The paper describes the details of the test as disclosed by the IIHS at the time of writing this paper (1, 2). In addition, the paper describes the performance of some of the bumper systems currently in production when subjected to this new test. The paper also describes a process to simulate the test with the help of some newly developed computer aided engineering (CAE) models and the resulting correlation to physical tests. Furthermore, the paper demonstrates how by using these correlated models the bumper-to-bumper compatibility can be improved through design parameters of the energy absorber. Finally, some of the differences in capabilities of injection molded energy absorbers vs traditional EPP foam energy absorbers with respect to the new IIHS deformable barrier test are explored through comparative testing.
Design Exploration of Bumper Systems Using Advanced CAE Techniques
Dhiraj Uikey, Darin A. Evans, Samir Abad, Ramesh Padmanaban
This paper describes the development of a design process tool, to explore the design of a bumper system, using advanced CAE techniques. It describes the utility of this tool to identify the main effects and interactions between various parameters of a bumper system on the functional objectives of the bumper system. Three case studies are presented to demonstrate the capabilities of the tool. In each case study, the critical parameters, affecting the performance criteria, were identified, parameterized, and given suitable ranges. A Finite Element Model morphing program (Morpher) was used to parameterize the finite element models. A design optimization and process integration software package was used to create DOE matrix and again the Morpher was used to generate rapid designs. The analysis was done in an explicit finite element analysis code. The data was post processed using the design optimization software and others.
Multiple Impact Prediction and Performance of Energy Absorbers
Eric Jaarda, Tansen Chaudhari, and Dhiraj Uikey
Low speed bumper impact performance relies on the capability of the energy absorber (EA) to absorb energy efficiently through multiple impacts. Series impacts are typically assessed via physical part testing due to the difficulties of predicting multiple impacts accurately. This paper describes a predictive engineering method used to assess the performance of injection molded thermoplastic energy absorber systems in multiple impacts.
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Multiple Impact Prediction and Performance of Energy Absorbers
Eric Jaarda, Tansen Chaudhari, and Dhiraj Uikey
Low speed bumper impact performance relies on the capability of the energy absorber (EA) to absorb energy efficiently through multiple impacts. Series impacts are typically assessed via physical part testing due to the difficulties of predicting multiple impacts accurately. This paper describes a predictive engineering method used to assess the performance of injection molded thermoplastic energy absorber systems in multiple impacts.
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