Title: Failure analysis and design of a front bumper using finite element method along with durability and rig tests

Authors: Ricardo R. Magalhaes; Cristiano H. Fontes; Silvio A.B. Vieira de Melo

Addresses: Department of Engineering, University of Lavras, Campus Universitário, 37200-000, Lavras, MG, Brazil ' Department of Industrial Engineering, University of Bahia, R. Aristides Novis, n. 2, Federação, 40210-630, Salvador, BA, Brazil ' Department of Industrial Engineering, University of Bahia, R. Aristides Novis, n. 2, Federação, 40210-630, Salvador, BA, Brazil

Abstract: This work presents a case study that comprises the application of the Finite Element Method (FEM) to the design of a front bumper to predict possible failures caused by fatigue. Stress distribution and damage estimates were obtained by using FEM together with rig tests results. Vehicle durability tests were also performed, and geometric changes were proposed in the design of the component analysed based on the simulation results obtained from FEM. A good agreement between experimental data and FEM predictions was found. The case study and results demonstrate that time and cost can be reduced in the course of the product development phase in the automotive industry. FEM also can be used to support decision-making during the design phase of the product.

Keywords: fatigue damage; front bumpers; finite element method; FEM; rig tests; vehicle durability; vehicle design; bumper design; failure analysis; stress distribution; simulation; product development; automobile industry; decision making; automotive bumpers.

DOI: 10.1504/IJVD.2012.049158

International Journal of Vehicle Design, 2012 Vol.60 No.1/2, pp.71 - 83

Received: 29 Mar 2011
Accepted: 05 Sep 2011
Published online: 23 Apr 2013 *

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