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

              2018-10-16 09:52:00
              LUQIMENG
              Original
              6955

              -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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