Journal of the Korean Society for Precision Engineering (한국정밀공학회지)

Korean Society for Precision Engineering (한국정밀공학회)
권호 표지
DOI QR코드

DOI QR Code

Investigation of Development of Bumper Back-Beam Using a Thermoplastic Polyolefin

열가소성 폴리올레핀으로 구성된 범퍼 후방 보 개발에 관한 연구

  • Received : 2012.04.26
  • Accepted : 2012.06.02
  • Published : 2012.08.01
Download PDF
⟨ Previous Next ⟩

Abstract

Recently, the application of the plastic material to automotive components and structures has steadily increased to satisfy demands on the saving of overall weight and the improvement of energy efficiency. The objective of this paper is to investigate the development of a bumper back-beam using a thermoplastic olefin (TPO). The bumper back-beam was designed to be manufactured from the injection molding process. In order to obtain a proper design of the bumper back-beam, three-dimensional finite element analyses were performed for various design alternatives. Stress-strain curves for different strain rates were measured by high speed tensile tests of the TPO to consider strain rate effects in the FEA. The influence of the sectional shape and the rib formation on the contact force-intrusion curves, the deflection and the energy absorption rate of the bumper back-beam was examined. From the results of the examination, a proper design of the bumper back-beam was acquired. The bumper back-beam consisting of TPO was fabricated from the injection moulding process and the vibration welding. Pendulum crash tests were carried out using the fabricated bumper back-beam. The results of the tests showed that the designed bumper back-beam can satisfy requirements of the federal motor vehicle safety standard (FMVSS). Through the comparison of the previously designed bumper back-beam with the newly designed bumper back beam, it was noted that the weight of the designed bumper back-beam is lighter than that of the previously designed bumper back beam by nearly 16 %. In addition, it was considered that the newly designed bumper back beam can improve recycling of the bumper back-beam.

Keywords

References

  1. Hoel, M. and Kverndokk, S., "Depletion of Fossil Fuels and the Impacts of Global Warming," Resource and Energy Economics, Vol. 18, No. 2, pp. 43-54, 1996.
  2. Park, C. W., Kwon, K. S., Kim, W. B., Min, B. K., Park, S. J., Sung, I. H., Yoon, Y. S., Lee, K. S., Lee, J. H., and Seok, J. W., "Energy Consumption Reduction Technology in Manufacturing - A Selective Review of Policies, Standards, and Research," Int. J. Precis. Eng. Manuf., Vol. 10, No. 5, pp. 151-173, 2009. https://doi.org/10.1007/s12541-009-0107-z
  3. Asnafi, N., Langstedt, G., Andersson, C. H., Ostergren, N., and Håkansson, T., "A New Lightweight Metal-Composite-Metal Panel for Application in the Automotive and Other Industries," Thin-Walled Structures, Vol. 36, No. 4, pp. 289-310, 2000. https://doi.org/10.1016/S0263-8231(00)00004-5
  4. Park, S. H., Ko, J. B., Choi, W. D., and Choi, M. Y., "A Study on the Effect of Metal Plate Position Design on Mechanical Strength during Lap Joint Dissimilar Friction Stir Welding Process of Aluminum Alloys," Journal of the KSPE, Vol. 27, No. 3, pp. 66-72, 2010.
  5. Friedrich, H. and Schumann, S., "Research for a "New Age of Magnesium" in the Automotive Industry," Journal of Materials Processing Technology, Vol. 117, No. 3, pp. 276-281, 2001. https://doi.org/10.1016/S0924-0136(01)00780-4
  6. Lee, S., Park, J., Koo, D., and Jung, B., "The Development of Material Technology Applied to Bumper Beam," Transactions of the Korean Society of Automotive Engineers, Vol. 10, No. 4, pp. 206-215, 2002.
  7. Li, Y., Lin, Z., Jiang, A., and Chen, G., "Use of High Strength Steel Sheet for Lightweight and Crashworthy Car Body," Materials & Design, Vol. 24, No. 3, pp. 117-182, 2003.
  8. Ning, H., Janowski, G. M., Vaidya, U. K., and Husman, G., "Thermoplastic Sandwich Structures Design and Manufacturing for the Body Panel of Mass Transit Vehicle," Composite Structures, Vol. 80, No. 1, pp. 82-91, 2007. https://doi.org/10.1016/j.compstruct.2006.04.090
  9. Marzbanrad, J., Alijanpour, M., and Kiasat, M. S., "Design and Analysis of an Automotive Bumper Back Beam in Low-speed Frontal Crashes," Thin-Walled Structures, Vol. 47, No. 8-9, pp. 902-911, 2009. https://doi.org/10.1016/j.tws.2009.02.007
  10. Puri, P., Compston, P., and Pantano, V., "Life Cycle Assessment of Australian Automotive Door Skins," International Journal of Life Cycle Assessment, Vol. 14, No. 5, pp. 420-428, 2009. https://doi.org/10.1007/s11367-009-0103-7
  11. Cheon, S. K., Choi, J. H., and Lee, D. G., "Development of the Composite Bumper Beam for Passengers Cars," Composite Structures, Vol. 32, No. 1-4, pp. 491-499, 1995. https://doi.org/10.1016/0263-8223(95)00078-X
  12. Sapuan, S. M., Maleque, M. A., Hameedullah, M., Suddin, M. N., and Ismail, N., "A Note on the Conceptual Design of Polymeric Composite Automotive Bumper System," Journal of Materials Processing Technology, Vol. 159, No. 2, pp. 145-151, 2005. https://doi.org/10.1016/j.jmatprotec.2004.01.063
  13. Hosseinzadeh, R., Shokrieh, M. M., and Lessard, L. B., "Parametric Study of Automotive Composite Bumper Beams Subjected to Low-velocity Impacts," Composite Structures, Vol. 68, No. 4, pp. 419-427, 2005. https://doi.org/10.1016/j.compstruct.2004.04.008
  14. Davoodi, M. M., Sapuan, S. M., Ahmad, D., Ali, A., Khalina, A., and Jonoobi, M., "Mechanical Properties of Hybrid Kenaf/Glass Reinforced Epoxy Composite for Passenger Car Bumper Beam," Materials & Design, Vol. 31, No. 10, pp. 4927-4932, 2010. https://doi.org/10.1016/j.matdes.2010.05.021
  15. Park, D. K., Jang, C. D., Lee, S. B., Heo, S. J., Yim, H. J., and Kim, M. S., "Optimizing the Shape of a Bumper Beam Section Considering Pedestrian Protection," International Journal of Automotive Technology, Vol. 11, No. 4, pp. 489-494, 2010. https://doi.org/10.1007/s12239-010-0060-y
  16. Davoodi, M. M., Sapuan, S. M., and Yunus, R., "Conceptual Design of a Polymer Composite Automotive Bumper Energy Absorber," Materials & Design, Vol. 29, No. 7, pp. 1447-1452, 2008. https://doi.org/10.1016/j.matdes.2007.07.011
  17. Gerrard, J. and Kandlikar, M., "Is European End-of Life Vehicle Legislation Living up to Expectations? Assessing the Impact of the ELV Directive on 'Green' Innovation and Vehicle Recovery," Journal of Cleaner Production, Vol. 15, No. 7, pp. 17-27, 2007. https://doi.org/10.1016/j.jclepro.2005.06.004
  18. Yoo, T. and Hong, J., "The Development of Eco- Friendly Recompound Material for Automotive Engine Under Cover with Recycling Used GMT Bumper Backbeam," Proceedings of Autumn Annual Meeting of Korean Society of Automotive Engineers, pp. 1488-1492, 2004.
  19. Lee, Y. K., Lee, H. S., and Nam, B. U., "Functional Polyolefin for Automotive," Polymer Science and Technology, Vol. 9, No. 1, pp. 4-11, 1998.
  20. Froelich, D., Maris, E., Haoues, N., Chemineau, L., Renard, H., Abraham, F., and Lassartesses, R., "State of the Art of Plastic Sorting and Recycling: Feedback to Vehicle Design," Minerals Engineering, Vol. 20, No. 9, pp. 902-912, 2007. https://doi.org/10.1016/j.mineng.2007.04.020
  21. http://www.nhtsa.gov/cars/rules/import/fmvss/index.html#P581
  22. http://www.nhtsa.gov/cars/rules/adaptive/Inoper/Index.html
  23. Kim, H. Y., Choi, J. G., Kim, S. B., Ha, D. Y., Lee, K. W., and Yeo, T. J., "Numerical Analysis of Bumper Back Beam Deformation Behavior in Test Conditions of Successive Impact," Proceedings of Spring Annual Meeting of Korean Society of Automotive Engineers, pp. 1308-1313, 2006.