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MECHANICAL ENGINEERING

Conceptual design and analysis of a car bumper using finite element method

ORCID Icon, , , , & ORCID Icon | (Reviewing editor) show all
Article: 1976480 | Received 18 Jun 2021, Accepted 30 Aug 2021, Published online: 17 Oct 2021

Figures & data

Figure 1. Configuration of common bumper (Lee et al., Citation2009)

Figure 1. Configuration of common bumper (Lee et al., Citation2009)

Figure 2. NCAP level for low-speed frontal impact (Hs, Citation2007)

Figure 2. NCAP level for low-speed frontal impact (Hs, Citation2007)

Figure 3. The nomenclature of the honeycomb (Thomas & Tiwari, Citation2019)

Figure 3. The nomenclature of the honeycomb (Thomas & Tiwari, Citation2019)

Figure 4. The original model of passenger vehicle frontal bumper

Figure 4. The original model of passenger vehicle frontal bumper

Figure 5. Design of perforated conceptual design of the car bumper

Figure 5. Design of perforated conceptual design of the car bumper

Figure 6. (a) Mesh independency graph. Variation of the stress values with a change in mesh size is illustrated. (b) Meshed bumper with a rigid wall

Figure 6. (a) Mesh independency graph. Variation of the stress values with a change in mesh size is illustrated. (b) Meshed bumper with a rigid wall

Table 1. Mechanical properties of aluminium alloy 5052 (Bhowmik & Srivas AK, Citation2016)(Bhowmik & Mishra, Citation2018)

Figure 7. (a) Equivalent Stress on the frontal fascia, (b) equivalent Stress on the outer case, (c) equivalent Stress on the honeycomb structure and (d) equivalent stress on the entire bumper (2 mm thickness)

Figure 7. (a) Equivalent Stress on the frontal fascia, (b) equivalent Stress on the outer case, (c) equivalent Stress on the honeycomb structure and (d) equivalent stress on the entire bumper (2 mm thickness)

Table 2. Equivalent stress values in different bumper parts

Figure 8. (a) Equivalent Stress on the frontal fascia, (b) equivalent Stress on the outer case, (c) equivalent Stress on the honeycomb structure and (d) equivalent stress on the entire bumper (4 mm thickness)

Figure 8. (a) Equivalent Stress on the frontal fascia, (b) equivalent Stress on the outer case, (c) equivalent Stress on the honeycomb structure and (d) equivalent stress on the entire bumper (4 mm thickness)

Table 3. Equivalent stress values in different bumper parts

Figure 9. Comparative analysis between 2 mm thickness and 4 mm thickness bumper

Figure 9. Comparative analysis between 2 mm thickness and 4 mm thickness bumper