Experimental investigation and crashworthiness analysis of 3D printed carbon PA automobile bumper to improve energy absorption by using LS-DYNA

Eyob Sisay Yeshanew; Gulam Mohammed Sayeed Ahmed; Devendra Kumar Sinha; Irfan Anjum Badruddin; Sarfaraz Kamangar; Ibrahim M Alarifi; Haitham M Hadidi

doi:10.1177/16878132231181058

Advances in Mechanical Engineering (Jun 2023)

Experimental investigation and crashworthiness analysis of 3D printed carbon PA automobile bumper to improve energy absorption by using LS-DYNA

Eyob Sisay Yeshanew,
Gulam Mohammed Sayeed Ahmed,
Devendra Kumar Sinha,
Irfan Anjum Badruddin,
Sarfaraz Kamangar,
Ibrahim M Alarifi,
Haitham M Hadidi

Affiliations

Eyob Sisay Yeshanew: Department of Mechanical Engineering, Institute of Technology, University of Gondar, Gondar, Ethiopia
Gulam Mohammed Sayeed Ahmed: Center of Excellence (COE) for Advanced Manufacturing Engineering, Program of Mechanical Design and Manufacturing Engineering, School of Mechanical, Chemical and Materials Engineering, ASTU, Adama, Ethiopia
Devendra Kumar Sinha: Center of Excellence (COE) for Advanced Manufacturing Engineering, Program of Mechanical Design and Manufacturing Engineering, School of Mechanical, Chemical and Materials Engineering, ASTU, Adama, Ethiopia
Irfan Anjum Badruddin: Mechanical Engineering Department, College of Engineering, King Khalid University, Abha, Saudi Arabia
Sarfaraz Kamangar: Mechanical Engineering Department, College of Engineering, King Khalid University, Abha, Saudi Arabia
Ibrahim M Alarifi: Department of Mechanical and Industrial Engineering, College of Engineering, Majmaah University, Al-Majmaah, Riyadh, Saudi Arabia
Haitham M Hadidi: Department of Mechanical Engineering, College of Engineering, Jazan University, Jazan, Saudi Arabia

DOI: https://doi.org/10.1177/16878132231181058
Journal volume & issue: Vol. 15

Abstract

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This research work aimed to enhance the crashworthiness of the existing automobile bumper to minimize crash injuries. As per the simulation results the weight of the carbon polyamide-based bumper is reduced in comparison with the existing steel bumper by 9.7 kg or 47.5%, with this reduction in weight 38% increase in fuel economy has been estimated. The energy absorption capability of carbon polyamide bumper is improved from the existing steel and aluminum bumper by 11.15% and 16.3% respectively and with this modification, the impact force is reduced from the existing steel bumper, which has 4.87 kN and aluminum alloy bumper, which has 4.10–1.86 kN. The crashworthiness parameter result analysis showed that the corrugated bumper geometry had a structural energy absorption (SEA), total energy absorption (TEA), and crush force efficiency (CFE) of 103.28 J/kg, 911 J, and 77.99%, which is higher than the hallow bumper geometry of 102.4 J/kg, 847 J, and 65.83% respectively. In addition to that, as the thickness of carbon polyamide bumper reduced from 4 mm to 3.5, 3, and 2.5 mm, deformation increased with a small rate from 13.5 mm to 16.7, 18.52, and 22.04 mm.

Published in Advances in Mechanical Engineering

ISSN: 1687-8132 (Print); 1687-8140 (Online)
Publisher: SAGE Publishing
Country of publisher: United Kingdom
LCC subjects: Technology: Mechanical engineering and machinery
Website: https://journals.sagepub.com/home/ade

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