Abstract:

The light-mass design was performed for front bumper and crash box in the front bumper assembly, which are the important components that influence automotive performance during front impact. The front bumper assembly was decoupled under the automotive collision condition according to the deformation process, the energy absorption characteristics and the transmission relationship of section force between different components of the front bumper assembly. The independent evaluation mode of the front bumper assembly was established. The light-mass design was performed by changing cross-section shapes and materials of structures  based on the independent evaluation mode. The light-mass solution was integrated with automotive, simulated by Ls-Dyna software and compared the performance. The results show that the scheme achieves a 30% lightmass effect with optimizing the collision waveform, the intrusion volume and the average structural force. Therefore, the light-mass design scheme of the front bumper assembly based on the independent evaluation mode is feasible.

Key words: automobile, passive safety, front bumper beam system, light-mass design, crash box, independent evaluation