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

                2018-10-16 09:52:00
                LUQIMENG
                Original
                4482

                -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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