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      1. Press-Hardened and Roll-Formed Lightweight Bumpers in Steels with Enhanced Strength

        2018-10-16 09:52:00
        LUQIMENG
        Original
        5385

        -Bumpers protect the BIW and external attributes in low speed collisions and contribute to crash safety in high speed collisions (transfer loads to the BIW).


        -They are continuously improved through implementation of materials with enhanced strength,new design features, new manufacturing processes, reduction of number of components andreduction of package space.





        Objectives:
        -Reduce weight of bumpers with roll-formed beams.
        -Manage high speed crash w/o rupture of materials or welds.
        -Fulfill world wide low speed crash requirements.
        -Investigate new materials with higher strength.


        Solution:
        -Beam section with modularity possibility and press-hardened crash boxes.


        Simulation set- - up
        -Three point bending.   


        Variables
        -Dimensional variations.
        -Automatic optimization.

        M- - profile
        -10.4% higher energy
        absorption / mass unit
        than benchmark beam.

               


        F ront bumper:
        -Cross beam 1200 MPa 1.2 mm.
        -Crash boxes PH 1200 MPa 1.2 mm.
        - Weight 6.37 kg = - - 13%  (compared to benchmark bumper). 


        Modularized:
        Section depth increased by 10 mm.



        Objectives:
        -Reduce the necessary package space for rear bumpers.
        -Manage high speed crash without rupture of materials or welds.
        -Fulfill world wide low speed crash requirements.
        -Investigate new press hardening materials with higher strength.


        Solution:
        -Implement patch technology on press hardened beam with deformable section.

        Innovation:
        -Patch technology – additional material only where
        needed.
        -For improved high speed crash performance.





        Front  bumper , press- - hardened beam and  crash boxes

        A beam in press-hardened un-coated quality with ~2000 MPa tensile strength isgood for crash applications, as are crash boxes in press-hardened three-layered 1200 MPa material.


        Using these materials can reduce the weight of a present front bumper by ~15%.



        Front b b umper , roll- - formed beam , press- - hardened crash boxes


        A beam with roll-formed M-profile in 1200 MPa is 10.4% lighter than benchmark roll-formed beam.
        The M-profile is possible to modularize, in order to increase the bending stiffness and/or adapt to fit
        with the package requirement.
        A beam with M-profile in 1200 MPa material and crash boxes in press-hardened 1200 MPa material
        is 13% lighter than benchmark bumper and still deliver superior crash performance.



        R ear b b umper , press- - hardened beam with patch
        A beam in press-hardened un-coated quality with ~2000 MPa tensile strength.
        The bumper fulfills world-wide low speed crash requirements.
        The bumper beam only experiences minor material failure in high speed impacts.
        The patch, including heat-affected zones, remain completely intact.

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