Crash Analysis and Size Optimization of a Vehicle’s Front Bumper System

Bumper beams and crash boxes are structural vehicle elements that have very critical functions during frontal collisions. This study examined the energy ab-sorbed by front bumper system reaction forces to cage structure representing cabin frame a full against rigid wall. For this purpose, 25 different analyses were conducted using ANSYS software changing sheet thickness values of beam (t1) boxes-frontal rails (t2) make up system. The internal (absorbed energy) from analysis results acting on representative struc-ture in opposite direction movement examined. When ob-tained data interpreted according variable thickness, it was observed t2 significantly affected both absorbed force results, while t1 did not significant effect results. Based this, value determined as design size optimization problem. problem established with reac-tion constraint solved, optimal highest / peak ratio found.