Optimization of Front Bumper Beam for RCAR Performance using Design of Six Sigma and Finite Element Analysis

Research Council for Automotive Repairs (RCAR) has developed a bumper test at 10 km/h to assess the damageability and repairing cost during a low speed collusion. For minimum damage and minimum repairing cost during low speed collusion it is necessary to design a bumper beam which provides structural stiffness and reduced deflection. Often it is challenging to design a front bumper beam to meet all safety requirements including, RCAR, high speed offset barrier and pedestrian protection, since these requirements are not necessarily compatible with each other. Design changes in rails and packaging constraints add to this challenge.

In this study, design of six sigma (DFSS) and finite element analysis are used to study the parameters that affect the stiffness and deflection of the front bumper beam. For the DFSS study, bumper beam geometry and reinforcements are investigated as control factors, vehicle rail widths as noise factors, and back of beam displacement and mass of front bumper system as the output response. The results show that the beam depth, horizontal rib thickness and width of bumper beam reinforcements are the most sensitive parameters to improve the RCAR performance of front bumper system.