Simulating the Complete Forming Sequence for a Roll Formed Automotive Bumper Beam Authors:
نویسندگان
چکیده
As part of the development of a new automotive bumper beam, a complete simulation of the entire forming process was carried out using LS-DYNA. The material for the beam was an ultra high strength steel presenting many challenges for the forming process. The sequence of forming operations was roll-forming (including forming a sweep in the initially straight roll-formed section), local annealing, forming of an initiator in the wall of the section and then crushing the end of the previously rolled section. The forming results (geometry, thinning and work hardening) were all transferred to the simulation of the bumper performance under various impact conditions. The paper describes the development of certain novel simulation techniques, particularly for the roll-forming for which the implicit analysis options of LS-DYNA were used, representation of the annealing process, as well as the method in which data was transferred between the various simulations. Above all, we describe how the simulations were used to guide the design of the bumper beam system up to the point of prototype manufacture and test.
منابع مشابه
EXPERIMENTAL POLYMERIC NANOCOMPOSITE MATERIAL SELECTION FOR AUTOMOTIVE BUMPER BEAM USING MULTI-CRITERIA DECISION MAKING METHODS
Material selection is a main purpose in design process and plays an important role in desired performance of the products for diverse engineering applications. In order to solve material selection problem, multi criteria decision making (MCDM) methods can be used as an applicable tool. Bumper beam is one of the most important components of bumper system in absorbing energy. Therefore, selecting...
متن کاملAlternative lightweight materials and component manufacturing technologies for vehicle frontal bumper beam
One of the vehicle subsystem where large advantage is expected in lightweight design is the bumper subsystems. Bumper subsystems are designed to prevent or reduce physical damage to the front or rear ends of passenger motor vehicles during collusion. In this paper, detail design aspects and method of analysis with particular reference to the application of composite materials to automotive fron...
متن کاملUniversiti Putra Malaysia Selection of Conceptual Design Using Analytical Hierarchy Process for Automotive Bumper Beam under Concurrent Engineering Environment Hambali
متن کامل
Composite Manufacturing Process Selection Using Analytical Hierarchy Process
This paper describes an approach, based on the analytical hierarchy process (AHP) that assists decision makers or manufacturing engineers determining the most appropriate manufacturing process to be employd in manufacturing of composite automotive bumper beam at the early stage of product development process. There are 5 types of processes under consideration namely injection moulding (IM), res...
متن کاملA computational design-of-experiments study of hemming processes for automotive aluminium alloys
Hemming is a three-step sheet-folding process utilized in the production of automotive closures. It has a critical impact on the performance and perceived quality of assembled vehicles. Using a two-dimensional finite element model, this paper presents a design-of-experiments (DOE) study of the relationships between important hemming process parameters and hem quality for aluminium alloy AA 6111...
متن کامل