Design and Parametric Study of Lightweight Aluminium Alloy Bumper Beams for Enhanced Crashworthiness Using the Finite Element Method

Abstract

The study focuses on improving the performance and efficiency of a vehicle bumper beam by addressing limitations in the baseline design, which uses Steel 350MC material with a thickness of 3 mm. The baseline design, though robust, is bulky, absorbs limited crushing energy during high-speed impacts, and contributes to reduced fuel efficiency due to its heavy weight. To address these challenges, a three-point bending test was employed to evaluate stiffness and energy absorption characteristics at the component level. Based on numerical simulations, three novel bumper beam designs were developed using aluminum alloy materials to achieve weight reduction while maintaining performance. Design of Experiments (DOE) was utilized to validate these designs through iterative three-point bending tests, identifying the optimal configuration using AA6056 material. The optimized bumper beam demonstrated a 61.29% reduction in mass, an 8.8% improvement in energy absorption, and no compromise in stiffness compared to the baseline. Furthermore, the optimized design was validated in a slow-speed RCAR (Research Council for Automobile Repairs) numerical simulation to ensure compliance with crashworthiness standards. Results confirmed the optimized bumper beam meets RCAR requirements, highlighting its suitability for real-world application. This research provides automakers with a lightweight, high-performance bumper beam design that enhances crashworthiness, reduces vehicle mass, and improves fuel efficiency, contributing to sustainable automotive innovation.