Impact Analysis of Automobile Bumper by using ANSYS Work
Bench
Ch. Raghu Babu1, Dr. Suresh J S2 1, PG Scholar, Department of Mechanical Engineering
2 Professor and HOD, Department of Mechanical Engineering
Ramachandra College of engineering, Eluru, West Godavari (Dist), AP, India. [email protected]
Abstract
Now a day’s bumper is used in vehicle which directly connected to chassis of vehicle. So that
when accidents are happened the force that transfer to other parts of vehicle through linkage.
There are no other supports to absorb that impact forces. So there is a design need to absorb
impact forces. For that reason here designed a new bumper system by Stiffeners. Stiffeners are
used to minimize the impact of accidents and it will resists or absorbs impact forces. The
objective of present study is to design and optimization of Automobile Bumper to avoid crashes
and for the safety of passengers and pedestrians so for many Authors have worked on
Automobile Bumper crash analysis and very few of them have focused on optimization of the
strength and weight. In our study we are on focused on impact analysis of automobile bumper
with high strength to weight ratio materials by using Ansys Workbench.
In this project, the new bumper system is designed using CREO and structural analysis is
done in ANSYS Workbench. For structural analysis of the bumper, here we made impact
analysis on existing (Maruti Alto) bumper with standard structure and honey comb structure at 9
different speeds such as 10km/hrto 90km/hr with 10Km/hr Intervalsby comparing with ABS
Plastic (Existed) to improve the overall performance of bumper.
Keywords- Bumper, Impact Forces, Stiffeners, CREO, ANSYS, Structural Analysis, ABS Plastic
1. INTRODUCTION
1.1 Bumper
A bumper is a structure attached to or integrated with the front and rear ends of a motor
vehicle, to absorb impact in a minor collision, ideally minimizing repair costs. Bumpers also
have two safety functions: minimizing height mismatches between vehicles, and protecting
pedestrians from injury. British inventor Frederick Simms invented bumpers in 1901.
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1.2History
Every day Car accidents are happening. Most troublesome situations are occurred to the
drivers that they can avoid such. The statistics shows that ten thousand dead and hundreds of
thousands to million wounded each year. Hence, improvement in the safety of automobiles is
prerequisite to decrease the numbers of accidents. Automotive bumper system is one of the key
systems in passenger cars. Bumper systems are designed to prevent or reduce physical damage to
the front or rear ends of passenger motor vehicles in collision condition. It protects the hood,
trunk, grill, fuel, exhaust and cooling system as well as safety related equipment such as parking
lights, headlamps and taillights, etc. A good design of car bumper must provide safety for
passengers and should have low weight. The function of automotive bumpers has changed
considerably over the past 70 years. The later performance is achieved by a combination of
careful design, material selection to obtain a particular balance of stiffness, strength and energy
absorption. Stiffness and Energy absorption are essential criterion. Stiffness is important because
vehicle design consideration limits the packaging space for the bumper design to deform under
load and Energy absorption is important because bumper must limit the amount of the impact
force transmitted to the surrounding rails and vehicle frame. Automotive bumper plays a very
important role in absorbing impact energy (original purpose of safety) and styling stand
point/aesthetic purpose. Now a day, automotive industry concentrates on optimization of weight
and safety.
Fig.-1 Chrome plated front bumper on a 1958 Ford Taunus
In 1971, the US National Highway Traffic Safety Administration (NHTSA) issued the
country's first regulation applicable to passenger car bumpers. Federal Motor Vehicle Safety
Standard No. 215 (FMVSS 215), "Exterior Protection," took effect on 1 September 1972— when
most automakers would begin producing their model year 1973 vehicles.
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1.3 Types of Bumpers
Standard Bumper
Deep Drop Bumper
Roll Pan Bumper
Step Bumper
Tube Bumper
1.3.1 Standard Bumper
Standard bumper is a structure attached to or integrated with the front and rear ends of a
motor vehicle, to absorb impact in a minor collision, ideally minimizing repair costs....Bumpers
ideally minimize height mismatches between vehicles and protect pedestrians from injury.
1.3.2 Deep Drop Bumper
This type of bumper is typically found on older trucks and is usually chrome plated. Deep
drop bumpers have a heavy-duty towing capacity and a lower ball height than a step bumper.
The drop from the bottom of the frame is usually 10 or 12 inches.
1.3.3 Roll Pan Bumper
Roll pan bumpers are typically found on custom compact trucks. The trailer hitches
available will sit in the middle, behind the bumper.
1.3.4 Step Bumper
This type of bumper is typically found on trucks, vans and SUVs. The small cut-out in
the centre looks like a step. This bumper also has holes for hitch balls and can be used to tow
lightweight trailers.
1.3.5 Tube Bumper: This type of bumper is typically found on jeeps.
Vehicle damageability would be improved in both these situations with taller front and
rear bumper beams. Real world claims data also show a significant number or crashes in which
damage is limited to the vehicle corners. Vehicle bumpers should prevent or limit much of the
damage sustained in these minor crashes. However, many vehicles do not have bumper
reinforcement beams that extend laterally much beyond the frame rails, leaving expensive
vehicle components such as headlamps and fenders (wings) unprotected.
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1. Geometry – vehicle bumpers need to be positioned at common heights from the
ground and extend laterally to the corners in order to properly engage other vehicles in low speed
crashes.
2. Stability – vehicle bumpers need to be tall and wide enough to remain engaged with
the bumpers of other vehicles despite vehicle motion due to loading, braking, etc.
1.4 Physics
Bumpers offer protection to other vehicle components by dissipating the kinetic energy
generated by an impact. This energy is a function of vehicle mass and velocity squared. The
kinetic energy is equal to 1/2 the product of the mass and the square of the speed. In formula
form:
𝐸𝑘 =1
2𝑀𝑣2
A bumper that protects vehicle components from damage at 5 miles per hour must be four times
stronger than a bumper that protects at 2.5 miles per hour, with the collision energy dissipation
concentrated at the extreme front and rear of the vehicle. Small increases in bumper protection
can lead to weight gain and loss of fuel efficiency.
2.LITERATURE REVIEW
[1]MAREK MAzuRKIEwrcz (1987), discussed on, In the United States, Federal
regulation FMVSS 215 (General guide for substantiation of compliance with FMVSS 214 and
215 CFR 581: Bumper Standard, pp. 9-81) requires that impact data of the front and rear
bumpers of cars be furnished for each make of vehicle. In this paper, the crash data of two
bumper beams are analysed by simulated computer models using the ABAQUS (Hibbitt,
Karlsson and Sorensen, Inc., Providence, RI, Version 4-S-171B) program. The salient feature of
the automatic time increment &ion scheme is used. Inelastic large deformation is considered.
Although sectional properties of the two beams and the initial impact condition are the same, the
technique used in selecting convergent tolerant is quite different due to the differences in
configuration. With due consideration good convergence can be achieved in less than 100 time
increments. Economically this compares very favourably to the actual testing during the initial
development process. The merits of crash simulation study are twofold: (I) providing economical
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evaluation of bumper capability; and (ii) serving to establish methods for comparing one bumper
to another for initial development purposes.
[2] Pradeep Kumar Uddandapu (2013), discussed on, Bumper is one of the main parts
which are used as protection for passengers from front and rear collision. The aim of this study
was to analyse and study the structure and material employed for car bumper in one of the car
manufacturer. In this study, the most important variables like material, structures, shapes and
impact conditions are studied for analysis of the bumper beam in order to improve the
crashworthiness during collision. The simulation of a bumper is characterized by impact
modelling using Pro/Engineer, impact analysis is done by SOILD WORKS according to the
speed that is 13.3 m sec-1 (48 km h-1) given in order to analyse the results. This speed is
according to regulations of Federal Motor Vehicle Safety Standards, FMVSS 208- Occupant
Crash Protection whereby the purpose and scope of this standard specifies requirements to afford
impact protection for passengers. In this research, analysis is done for speed according to
regulations and also by changing the speeds. Simulation using Finite Element Analysis software,
which is SOILD WORKS, was conducted. The material used for bumper is CARBON FIBER-
REINFORCED POLY-ETHER-IMIDE PEI and ABS Plastic.
[3] A.T. Beyene (2014), discussed on, Automobile bumper subsystem is the frontal and
rear structure of the vehicle that has the purpose of energy absorption during low velocity
impact. The main component of this subsystem is the transverse bumper beam, generally made
by steel. Design of vehicle subsystem for lightweight and for safety seems to lead the designer
toward opposite directions. Quite interesting solutions can be obtained with the use of composite
Materials. This paper is analysing some possible alternative solutions for the particular case of
the front and rear bumper.
[4]Bhavesh A. Bohra (2014), discussed on, an automobile's bumper is the front-most or
rear-most part, designed to allow the car to sustain an impact without damage to the vehicle's
safety systems. They are not capable of reducing injury to vehicle occupants in high-speed
impact. In this paper, review of the most important variables like material, structures, shapes and
impact conditions are studied for analysis of the bumper beam in order to improve the
crashworthiness during collision. More emphasis is given on selection of bumper material.
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3. MODELING AND ANALYSIS OF BUMPER
1. Study the literature related to bumper design and its performance improvement by referring
to books, journal papers and related manuals.
2. Obtaining design data of existing bumper model.
3.3D modelling of bumper model in ANSYS Workbench.
4. Selection of bumper material in accordance with design.
5. Theoretical calculation of impact force on bumper system as well as by using Ansys
Workbench
6. Analysis of part being designed using ANSYS Workbench
7. Calculation of Von- Moises stress and displacement and comparing the results obtained.
CREO
Creo Elements is a software application within the CAID/CAD/CAM/CAE category. Creo
Elements is a parametric, feature-based modelling architecture incorporated into a single
database philosophy with rule-based design capabilities. It provides in-depth control of complex
geometry, as exemplified by the trajpar parameter. The capabilities of the product can be split
into the three main headings of Engineering Design, Analysis and Manufacturing. This data is
then documented in a standard 2D production drawing or the 3D drawing standard ASME
Y14.41-2003.
Fig. - 3. Assembly of Bumper Fig. -4 Assembly of Bumper (Honeycomb structure)
Introduction about ANSYS15.0
Ansys Aim
ANSYS AIM demonstrates the vision of ANSYS 3D Multi physics Simulation in ANSYS
Workbench. In part, ANSYS AIM offers:
• An integrated single window display for end-to-end simulation, including geometry, meshing,
solution, post-processing and design point evaluation.
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• A guided simulation process through the use of templates and task-based windows.
• A common look-and-feel for fluid, structural, and thermal physics simulation technologies.
• Bi-directional CAD geometry access and integrated geometry preparation including reference
frames, model configuration, and suppression.
• Engineering topology creation for flow volume extraction.
• Automatic meshing based on engineering intent for fluid, structural, and thermal physics.
• A customizable user interface to select, create, and navigate operations.
• Consistent scripting and journaling throughout the simulation process.
• Full use of expressions for all model inputs.
• Ease of use actuated by pervasive reuse of data, parameterization.
• Results exploration combined with quantitative post-processing.
• Context-sensitive help and supporting documentation.
In addition to the ANSYS AIM documentation set, you can also reference the Workbench
Scripting Guide for information on using the journaling and scripting capabilities within ANSYS
AIM.
Deformations and von-mises stress diagrams
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Analytical Method
We considered Maruti Suzuki Alto Car Bumper for design
Mass of car =730kg
Mass of four passengers = 300kg i.e., 75kg each
Total Mass = 730 +300; m = 1030kg
F=m * a
Here, F – Net Force in N; m - Mass in Kg
a - Acceleration in m/s2
a = 𝒗−𝒖
𝒕
v- Final velocity (m/s); u- initial velocity (m/s); t- time (s)
Assumptions
1. Initial Velocity = 0 m/s
2. Time = 1 s
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For V = 10kmph
V = 10* 5
18
v = 2.77m/s
a =𝒗−𝒖
𝒕
a = 2.77−0
1
= 2.77 m/s
F=m*a
F=1030* 2.77
=2853N
For V = 20kmph
V = 20 * 5
18
v = 5.5 m/s
a =𝒗−𝒖
𝒕
a = 5.5−0
1
= 5.5m/s
F=m*a
F=1030* 5.5
F=5665 N
For V = 30Kmph
V = 30*5
18
V = 8.3 m/s
a = 𝒗−𝒖
𝒕
a = 8.3−0
1
= 8.3 m/s
F = m*a
F = 1030*8.3
F = 8549 N
For V = 40Kmph
V = 40*5
18
V = 11.1 m/s
a = 𝒗−𝒖
𝒕
a = 11.1−0
1
= 11.1 m/s
F = m*a
F = 1030*11.1
F = 11433 N
For v = 50Kmph
V = 50*5
18
V = 13.88 m/s
a = 𝒗−𝒖
𝒕
a = 13.88−0
1
= 13.88 m/s
F = m*a
F = 1030*13.88
F = 14296.4 N
For V = 60Kmph
V = 60*5
18
V = 16.66 m/s
a = 𝒗−𝒖
𝒕
a = 16.66−0
1
= 16.66 m/s
F = m*a
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F = 1030*16.66
F = 17159.8 N
For V = 70Kmph
V = 70*5
18
V = 19.44 m/s
a = 𝒗−𝒖
𝒕
a = 19.44−0
1
= 19.44 m/s
F = m*a
F = 1030*19.44
F = 20023.2
For V = 80Kmph
V = 80*5
18
V=22.22 m/s
a = 𝒗−𝒖
𝒕
a = 22.22−0
1
= 22.22 m/s
F = m*a
F = 1030*22.22
F = 22886.6 N
For V = 90Kmph
V = 90*5
18
V = 25 m/s
a = 𝒗−𝒖
𝒕
a = 25−0
1
= 25 m/s
F = m*a
F = 1030*25
F = 25750 N
4. RESULTS AND DISSCUSSION
Bumper with ABS Plastic at different speeds
Table-4.1 Bumper with ABS Plastic at different speeds
SNo. Cross Section Total
Deformation(mm) Von Mises Stresses(MPa)
SPEED
1
Existing Bumper 155.81 247.86 90KMPH
Honeycomb
Bumper
142.45 223.23
2
Existing Bumper 140.33 207.82 80KMPH
Honeycomb
Bumper
126.63 198.44
3
Existing Bumper 122.80 181.84 70KMPH
Honeycomb
Bumper
110.80 173.63
4
Existing Bumper 103.87 165.23 60KMPH
Honeycomb
Bumper
94.96 148.82
5
Existing Bumper 87.83 130.05 50KMPH
Honeycomb
Bumper
79.14 124.03
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6
Existing Bumper 70.17 103.91 40KMPH
Honeycomb
Bumper
63.31 99.21
7
Existing Bumper 51.94 82.62 30KMPH
Honeycomb
Bumper
47.48 74.41
8
Existing Bumper 35.08 51.95 20KMPH
Honeycomb
Bumper
31.65 49.60
9
Existing Bumper 17.55 25.97 10KMPH
Honeycomb
Bumper
15.82 24.80
5. CONCLUSIONS
1. The impact analysis is done at different speeds i.e.10kmph, 20kmph, 30kmph, 40kmph,
50kmph, 60kmph, 70mph, 80kmph & 90kmph for a bumper model for ABS plastic material with
existing model and honey comb model.
2. From the results, it is concluded that the honey comb model is having more strength i.e. less
deformation at different speeds than existing model.
REFERENCES
[1]MAREK MAzuRKIEwrcz and YEI LUNG TIEN, “CRASH SIMULATION OF
BUMPERS”, Vol 26. No. 5. pp. 141-741. 1987.
[2] Pradeep Kumar Uddandapu,“Impact Analysis on Car Bumper by varying speeds using
Materials ABS Plastic and Poly Ether Imide by Finite Element Analysis software Solid works”,
Vol.3, Issue.1, Jan-Feb. 2013 pp-391-395.
[3] A.T. Beyenea, E.G. Korichob, G. Belingardib, B. Martoranac, “Design and manufacturing
issues in the development of lightweight solution for a vehicle frontal bumper”, Procedia
Engineering 88 (2014) 77 – 84.
[4] Bhavesh A. Bohra, Prof. D. B.Pawar,”Comparative analysis of frontal car bumper during
impact”,Volume 3, Issue 12, December 2014.
[5] S Jeyanthi and J Janci Rani,“High velocity Impact Analysis of the Thermoplastic Bumpers in
Automobiles”,Vol. 73, January 2014, pp. 66-68 .
[6] Alen John, Nidhi M.B, “Modeling and Analysis of an Automotive Bumper Used for a Low
Passenger Vehicle”, Volume 15 Number 7 – Sep 2014.
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[7] KUSEKAR SAMBHAJI KASHINATH, CHUNGE ABHIJIT BALASAHEB, “REVIEW OF
DESIGN & ANALYSIS OF BUMPER BEAM IN LOW SPEED FRONTAL CRASHES”,
Volume- 2, Issue- 2, Feb.-2014.
[8] E. S. Roopesh, L. Bhaskara Rao,“Design and Analysis of an Automotive Frontal Bumper
Beam for Low-Speed Crashes”,Vol. 2 Issue 5, May – 2015.
[9] Anurag Dubey, Kumar Gautam Jha,“Technological Properties and Processing Technologies
of Composite Material: Design and Manufacturing of Composites”,Volume 29 Number 4 -
November 2015.
[10] R.Ranjithkumar, J.P.Ramesh,“MODELLING AND ANALYSIS OF A CAR BUMPER
USING VARIOUS MATERIALS BY FEA SOFTWARE”,April 2015.
[11] Rizul Kumar, Pranav Jain and Hemant Chouhan,“Low Velocity Impact Analysis on Bumper
Reinforcement Sections”,Volume 2, Number 2; April-June, 2015 pp. 76-78.
[12] Suresh Doddi, Dr. Maruthi B H, Dr. K. Channakeshavalu, Chandru.B.T,“Experimental-
Numerical Modal and Impact Analysis of Car Bumper”,Vol. 4 Issue 06, June-2015.
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