International Journal of Research and Innovation (IJRI)

International Journal of Research and Innovation (IJRI)

1401-1402

REDUCTION OF IMPACT EFFECT ON CAR BUMPER USING

MEMORY SHAPE ALLOY PADS.

M.Arun Kumar, 1, Y Anil Reddy2, Godi Subba Rao3,

1 Research Scholar, Department of Mechanical Engineering, Hyderabad Institute of Technology and Management, Hyderabad, India
2 Assistant professor, Department of Mechanical Engineering, Hyderabad Institute of Technology and Management,Hyderabad, India
3 professor, Department of Mechanical Engineering, Hyderabad Institute of Technology and Management, Hyderabad, India

Abstract
Bumper is one of the most important parts in passenger cars for which the material and structure should
be considered in order to reduce the impact of collision. Since suitable impact strength is the main expectation for such a structure, the authors survey the variables that directly give impact characteristics and
wished for easily achievable modifications resulting from impact modeling on commercial bumpers. Many
researchers have studied that accident always occurs in front side. The impressed the authors to study
and analyses the component related to frontal crash and therefore, the authors selected bumper.
Aim of the project work is reduce the effort of car bumper by introducing honey comb structure instead of
regular rubber block as impact block.
Initially data collection and literature survey will be done to understand the problem and rectification
methodology.
A parametric model and design will be prepared using reverse engineering process.
Structural analysis will be carryout on regular and with honey comb structured damper pad with rubber
and NITINOL material as a damper element.
Impact analysis will be carryout on bumper with honey comb structured damper pad.
Comparison will be done between result of traditional and honey comb structured bumper pad.
Graphs and tables will be prepared for easy understanding and comparison.

*Corresponding Author:
M.Arun Kumar,
Research Scholar, Department of Mechanical Engineering, Hyderabad Institute of Technology and Management, Hyderabad,
India
Published: July 04, 2015
Review Type: peer reviewed
Volume: I, Issue : IV

Citation: M.Arun Kumar, Research Scholar (2015)

REDUCTION OF IMPACT EFFECT ON CAR BUMPER
USING MEMORY SHAPE ALLOY PADS.

PROBLEM DESCRIPTION AND METHODOLOGY

Car bumper is used for the protection of passengers, generally steel or impact grade plastics are used as bumper
material along with rubber pads between chassis and
bumper.
As per the previous research passengers protection can
be increased up to 34% by increasing bumper thickness.
But the percentage of passenger safety is not satisfactory
even after modifications.
This is an attempt to increase the passengers safety by
implementing honey comb structure and (NITINOL) memory shape alloy which is used as damper strings.
The following process will be followed to increase passengers safety.
1)Parametric model will be created to conduct analysis.
2)Structural analysis will be conducted on normal model
to evaluate the results ( for comparison purpose).
3)Analysis will be carried out by changing bumper materials.

4)Honey comb structure pad with rubber and memory

shape alloy will be analyzed to determine impact conditions.
INTRODUCTION TO BUMPER OF A CAR
An automobile's bumper is the front-most or rear-most
part, ostensibly designed to allow the car to sustain an
impact without damage to the vehicle's safety systems.
They are not capable of reducing injury to vehicle occupants in high-speed impacts, but are increasingly being
designed to mitigate injury to pedestrians struck by cars.
First standards
In 1971, the U.S. National Highway Traffic Safety Administration (NHTSA) issued the country's first regulation applicable to passenger car bumpers. Federal Motor Vehicle
Safety Standard No. 215 (FMVSS 215), "Exterior Protection," took effect on 1 September 1972 when most automakers would begin producing their model year 1973
vehicles. The standard prohibited functional damage to
specified safety-related components such as headlamps
and fuel system components when the vehicle is subjected to barrier crash tests at 5 miles per hour (8 km/h) for
front and 2.5 miles per hour (4 km/h) for rear bumper
systems. In October 1972, the U.S. Congress enacted the
Motor Vehicle Information and Cost Saving Act (MVICS),
which required NHTSA to issue a bumper standard that
yields the "maximum feasible reduction of cost to the
public and to the consumer". Factors considered included the costs and benefits of implementation, the standard's effect on insurance costs and legal fees, savings in
consumer time and inconvenience, and health and safety
considerations.
The 1973 model year passenger cars sold in the U.S. used
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International Journal of Research and Innovation (IJRI)

a variety designs. They ranged from non-dynamic versions with solid rubber guards, to "recoverable" designs
with oil and nitrogen filled telescoping shock-absorbers.
The standards were further beefed up for the 1974 model
year passenger cars with standardized height front and
rear bumpers that could take angle impacts at 5-mile-perhour (8 km/h) with no damage to the car's lights, safety
equipment, and engine. This often meant additional overall vehicle length, as well as new front and rear designs to
incorporate the stronger energy absorbing bumpers.
TYPES OF BUMPERS
PLASTIC BUMPER
CARBON FIBRE BUMPER
BOBY KIT BUMPER
STEEL BUMPER
PLASTIC BUMPER
Most modern cars use a reinforced thermoplastic bumper, as they are cheap to manufacture, easy to fit and absorb more energy during a crash. A majority of car bumpers are custom made for a specific model, so if you are
looking to replace a cracked bumper with a similar one,
you would have to buy from a specialist dealer. However,
many companies now offer alternative designs in thermoplastic, with a range of fittings designed for different
models.

location of a feature, the physical lines on the drawing

must be changed (in each affected view) then associated
dimensions are updated. When using parametric modeling, the features are driven by the dimensions (parameters). To modify the diameter of a hole, the hole diameter
parameter value is changed. This automatically modifies
the feature wherever it occurs - drawing views, assemblies, etc. Another unique attribute of Creo2.0 (PRO/ENGINEER)is that it is a solid modeling program. The design
procedure is to create a model, view it, assemble parts as
required, then generate any drawings which are required.
It should be noted that for many uses of Pro/E, complete
drawings are never created. A typical design cycle for a
molded plastic part might consist of the creation of a solid
model, export of an SLA file to a rapid prototyping system
(stereolithography, etc.), use of the SLA part in hands-on
verification of fit, form, and function, and then export of
an IGES file to the molder or toolmaker. A toolmaker will
then use the IGES file to program the NC machines which
will directly create the mold for the parts. In many such
design cycles, the only print created will be an inspection
drawing with critical and envelope dimensions shown.

MODEL OF CAR BUMPER

BOBY KIT BUMPER

Modified cars often now have a full body kit rather than
just a front and rear bumper. These kits act as a skirt
around the entire body of the car and improve performance by reducing the amount of air flowing underneath
the car and so reducing drag. Due to each car's specifications, these have to be specially purchased and can
be made from thermoplastic, like a standard bumper, or
even out of carbon fiber.
CARBON FIBRE BUMPER
Carbon fiber body work is normally the thing of supercars, but many car companies, and specialist modifiers,
are starting to use it for replacement body part on everyday cars. This is because it is very light and is safe during
a crash. It is, however, a lot more expensive than normal
thermoplastic.

The above image shows assembly of car bumper with regular

damper pad

STEEL BUMPER
Originally plated steel was used for the entire body of a
car, including the bumper. This material worked well, as
it was very strong in a crash, but it was very heavy and
dented performance. As car engine design has improved,
steel bumpers have pretty much disappeared for anything
except classic cars. Replacing one involves a lot of searching for scrap cars or having one specially made.

The above image shows assembly of car bumper with honey

comb damper pad

INTRODUCTION TO CREO2.0 (PRO/ENGINEER)

Creo2.0 (PRO/ENGINEER)is a feature based, parametric
solid modeling program. As such, it's use is significantly
different from conventional drafting programs. In conventional drafting (either manual or computer assisted), various views of a part are created in an attempt to describe
the geometry. Each view incorporates aspects of various
features (surfaces, cuts, radii, holes, protrusions) but the
features are not individually defined. In feature based
modeling, each feature is individually described then integrated into the part. The other significant aspect of conventional drafting is that the part geometry is defined by
the drawing. If it is desired to change the size, shape, or

The above image shows honey comb structure damper pad

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International Journal of Research and Innovation (IJRI)

IMPACT LOAD CONDITIONS

Speed1=100kmph
For 100kmph&150kmph
FS=1/2mv2
F=1/2(mass)(velocity)2 /s(slowdown)
F=force acting on car bumper
M=mass of the vehicle (1950)
V=velocity in m/s
S=slow down distance=0.5m
1.For 100kmph(27.7)velocity
=100*1000/3600=27.7m/s
F=1/2(2000)(27.7)2/(0.5)=1534.580kn
=1534580n
Pressure=1534580/Area174159484=13.49n/mm2=MPA
Speed2=150kmph
For150KMPH(41.55)(Velocity)
=150*1000/3600=41.55
=F=1/2(2000)(41.55)2/(0.5)=20.325MPA

The above image shows displacement

MATERIALS AND BOUNDARY CONDITIONS

ALLOY STEEL
E-GLASS EPOXY
S-GLASS EPOXY
RUBBER
NITINOL (memory shape alloy)

STRUCTURAL ANALYSIS OF CAR BUMPER WITH

DAMPER AT SPEED 1

The above image shows imported model

The above image shows strain

MATERIAL E- GLASS AND RUBBER

The above image shows stress

MATERIAL S- GLASS AND RUBBER

The above image shows meshed model

MATERIAL STEEL AND RUBBER

The above image shows stress

The above image shows stress

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International Journal of Research and Innovation (IJRI)

STRUCTURAL ANALYSIS OF CAR BUMPER WITH

DAMPER AT SPEED 2
MATERIAL STEEL AND RUBBER

MATERIAL E- GLASS AND RUBBER

The above image shows stress

The above image shows stress

MATERIAL E- GLASS AND RUBBER

MATERIAL S- GLASS AND RUBBER

The above image shows stress

The above image shows stress

MATERIAL S- GLASS AND RUBBER

STRUCTURAL ANALYSIS OF CAR BUMPER WITH HONEY COMB DAMPER AT SPEED 2

MATERIAL STEEL AND RUBBER

The above image shows stress

STRUCTURAL ANALYSIS OF CAR BUMPER WITH HONEY COMB DAMPER AT SPEED 1

MATERIAL STEEL AND RUBBER

The above image shows stress

The above image shows stress

MATERIAL E- GLASS AND RUBBER

The above image shows stress

MATERIAL S- GLASS AND RUBBER

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International Journal of Research and Innovation (IJRI)

STRUCTURAL ANALYSIS OF CAR BUMPER WITH HONEY COMB DAMPER AT SPEED 1

MATERIAL S- GLASS AND NITINOL

The above image shows strain

The above image shows stress

GRAPHS

The above image shows displacement

The above image shows displacement graph

STRUCTURAL ANALYSIS OF CAR BUMPER WITH HONEY COMB DAMPER AT SPEED 2

MATERIAL S- GLASS AND NITINOL

The above image shows strain graph

The above image shows stress

IMPACT ANALYSIS OF CAR BUMPER WITH HONEY

COMB DAMPER AT SPEED 2
MATERIAL S- GLASS AND NITINOL

STRUCTURAL ANALYSIS
Car bumper plain dumper pad
steel

E glass

S glass

Speed1

Speed2

Speed1

Speed2

Speed1

Speed2

Stress

39.58

59.67

40.31

60.77

40.14

60.15

Displacement

1.36

2.06

3.95

5.96

0.329

0.49

Strain

0.0109

0.0165

0.0316

0.047

0.0026

0.0039

Honey comb

The above image shows stress

Stress

32.97

50.17

33.69

50.78

33.59

50.64

Displacement

1.35

2.07

3.97

5.99

0.3314

0.49

Strain

0.011

0.00013

0.00024

0.00037

2.100082e-5

3.16676e-5

Car bumper (s glass) & dumper (memory shape alloy)

Speed 1

Speed 2

Stress

20.09

40.11

Displacement

0.206

0.395

strain

1.30751e-5

2.5085e-5

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CONCLUSION
This thesis work is done to determine about reduction of
impact effect on car bumper using honey comb technology.
Data collection and literature survey is done for the methodology.
As per literature survey 34% safety can be increased.
3D models are prepared for further analysis approach.
Structural analysis is done on general model to evaluate
the result for the comparison purpose.
Structural analysis is done on bumper by changing the
material to CRFP (carbon reinforced fiber polymers).
This material is choose due to its higher yield and compressive strength with in low density/weight.
Analysis was conducted by implementing rubber & memory shape alloy blocks with honey comb structure instead
of plain pad.
Impact analysis is done on the selected model to determine FOS of car bumper at high speed collision.
As per the analytical results this project concludes that
car bumper with S-Glass epoxy (CRFP) along with NITINOL honey comb pad work better than previous models
and it increases passenger safety by 70% (while comparing FOS).
Note: S-glass is a low density carbon material with higher
structural stability.
Honey comb technology is widely used in Aerospace
domine due to its higher strength at very low volume of
material (low weight due to honey comb cuttings).
NITINOL is basically a stress based memory shape alloy
which regains its original state/shape at the removing
stress/load.
This material is widely used in dampers.
REFERENCES
1). Material selection of polymeric composite automotive
bumper beam using analytical hierarchy process(1)
A. Hambali1, s. M. Sapuan1, n. Ismail1, y. Nukman2
1. Department of mechanical and manufacturing engineering, universiti putra malaysia,
43400 Upm serdang, selangor, malaysia;
2. Department of engineering design and manufacture,
university of malaya,
50603 Kuala lumpur, malaysia
2). Research on the crash safety of the car bumper base
on the different standards(2)
Q. H. Ma 1, c. Y. Zhang 2, s. Y. Han 3 and z. T. Qin4
1 Shanghai univ engn sci, college of automotive engineering,
Shanghai 201620, peoples r china
2 Shanghai univ engn sci, college of mechanical engineering
Shanghai 201620, peoples r china
3). Effect of the strengthened ribs in hybrid toughened
kenaf/ glass epoxy composite bumper beam(3)
M.M. Davoodi 1, s.M. Sapuan 1, aidy ali 1, d. Ahmad 2
1. Department of mechanical and manufacturing engineering, universiti putra malaysia, 43400 upm serdang,
Selangor, malaysia
4).Influence of natural long fiber in mechanical, thermal
and recycling properties of thermoplastic composites in
automotive components (4)
S. Jeyanthi* and j. Janci rani
Department of automobile engineering, mit, anna university, chennai, india
5). Impact analysis on car bumper by varying speeds using materials abs plastic and poly ether imides by finite
element analysis(5)
Pradeep kumar uddandapu assistant professor ,dept of

mechanical engineering, k.S.R.M college of engg, kadapa,

andhra pradesh, india
6).Impact analysis of a car bumper for various speeds using
Carbon fiber reinforced poly ether imide and s2
Glass epoxy materials by solid works software(6)
1V.Mohan srikanth, 2k.Venkateswara rao, 3m.Sri rama
murthy
1Sir c.R.Reddy college of engineering, eluru, ap, india
7).Design of the crash deterrent bumper for heavy vehicle
to car collision
Hrishikesh gadage, siddharth dhamke and pravin jadhav
School of mechanical and building science, vit university,
vellore, india.
E-mail: hrishikesh.Bapusaheb2013@vit.Ac.In, dhamkesiddharth.Vinayak2013@vit.Ac.In
Pravin.Dnyaneshwar2013@vit.Ac.In
8). Impact analysis of front bumper (8)
Mr. Nitinoln s. Motgi prof. S. B. Naik prof.P.R.Kulkarni
Me design ii, walchand instituteof technology,solapur
(india)
Associate professor, walchand
Institute of technology, solapur(india)
Associate professor, walchand

author

M.Arun kumar
Research Scholar,
Department Of Mechanical Engineering,
HyderabadInstituteOf Technology And Management,
Hyderabad,India

Y Anil Reddy (project Guide)

Assistant professor
Department Of Mechanical Engineering,
HyderabadInstituteOf Technology And Management,
Hyderabad,India

Godi Subba Rao, (HOD)

Professor,Department Of Mechanical Engineering,
HyderabadInstituteOf Technology And Management,
Hyderabad,India

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