Optimization of Monoblock Bumper

• Main Author: Norberg, Johannes
• Format: Bachelor Thesis
• Language: English
• Published: 2007
• Subjects: Technology; crash test; monoblock bumper; Teknik; Luleå
• Online Access: http://urn.kb.se/resolve?urn=urn:nbn:se:ltu:diva-59393

The monoblock bumper is a new bumper design concept developed at Gestamp R&D in Luleå. The original idea with the concept was to replace all parts in a traditional bumper system with one single component, but in the present situation, additional reinforcement components are often used to gain sufficient performance. This master thesis report describes an optimization process of a reinforced monoblock bumper system. The purpose with this thesis was to create guidelines regarding the reinforcement design and to evaluate the general affects of using reinforcements. Both in terms of crash test performance and deformation robustness. Reinforcement concepts were generated and evaluated with both crash test simulations and real crash tests. General analyses were also performed regarding reinforcement positioning in the bumper, and reinforcement influence on deformation robustness. Finally, an optimized reinforced bumper system was presented as a possible alternative to the original bumper. The final reinforced bumper system is 14% lighter than the original bumper system without reinforcement. This should save the additional costs of manufacturing and mounting of the reinforcement with good margin. The reinforcements have also proven to make the bumper system easier to optimize towards a specific crash test. A simple change of the reinforcement position is often enough. A couple of new ideas on how to mount the reinforcement in the bumper have also been generated during this project. Validerat; 20101217 (root)