The document discusses challenges in developing bumpers for vehicles to meet multi-regional requirements. It summarizes bumper technologies and the hot stamping process. Key challenges include adapting bumper designs to meet changes to European low-speed tests, like a new 10 degree barrier angle for the AZT test, and meeting requirements for North American tests from IIHS, like its small overlap frontal crash test which requires stiffer bumpers to control vehicle movement and overlap with barriers. Adapting bumper designs for different regions requires considering changes to materials, shapes, and energy absorbing structures.
The document discusses challenges in developing bumpers for vehicles to meet multi-regional requirements. It summarizes bumper technologies and the hot stamping process. Key challenges include adapting bumper designs to meet changes to European low-speed tests, like a new 10 degree barrier angle for the AZT test, and meeting requirements for North American tests from IIHS, like its small overlap frontal crash test which requires stiffer bumpers to control vehicle movement and overlap with barriers. Adapting bumper designs for different regions requires considering changes to materials, shapes, and energy absorbing structures.
The document discusses challenges in developing bumpers for vehicles to meet multi-regional requirements. It summarizes bumper technologies and the hot stamping process. Key challenges include adapting bumper designs to meet changes to European low-speed tests, like a new 10 degree barrier angle for the AZT test, and meeting requirements for North American tests from IIHS, like its small overlap frontal crash test which requires stiffer bumpers to control vehicle movement and overlap with barriers. Adapting bumper designs for different regions requires considering changes to materials, shapes, and energy absorbing structures.
The document discusses challenges in developing bumpers for vehicles to meet multi-regional requirements. It summarizes bumper technologies and the hot stamping process. Key challenges include adapting bumper designs to meet changes to European low-speed tests, like a new 10 degree barrier angle for the AZT test, and meeting requirements for North American tests from IIHS, like its small overlap frontal crash test which requires stiffer bumpers to control vehicle movement and overlap with barriers. Adapting bumper designs for different regions requires considering changes to materials, shapes, and energy absorbing structures.
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Hot Stamped bumper design
challenges in development for meeting multi-regional (new) requirements.
Dr. Achim Kroening Benteler Automotive - Structures -
www.autosteel.org
Page 1
Agenda Bumper Technology and Customer Portfolio The Hot Stamping Process - Material, Process, Performance, Design
Challenges in the bumper development for multi regional requirements :
- Europe (Changes, effect and conclusion) - North America (Changes, effect and conclusion)
t = 3,4 mm t = 3,0 mm t = 2,5 mm t = 2,2 mm t = 2,5 mm t = 2,2 mm
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Page 3
Benteler US-Bumper Examples in Production
Developedfor forUS/Canada US/Canada Developed requirements requirements
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Page 4
The Hot Stamping process
direct process
press coil blank furnace handling cooling
indirect process
press coil blank
(pre-forming / trimming)
press furnace handling cooling
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Page 5
Material Overview - Steel Grades
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Page 6
Crash Performance of DB200 Hot Stamped
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Page 7
High Design Flexibility with Hot Stamped design
Peugeot 407 Front Bumper
BMW E63 Rear Bumper
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Page 8
Agenda Bumper Technology and Customer Portfolio The Hot Stamping Process - Material, Process, Performance, Design
Challenges in the bumper development for multi regional requirements :
- Europe (Changes, effect and conclusion) - North America (Changes, effect and conclusion)
www.autosteel.org
Page 9
European low speed Test Specifications
ied f i d mo
Pendulum Tests ECE R42
Offset Barrier AZT Test Thatcham
front
Barrier angle Position
rear
Barrier angle Barrier mass Position
Remark: High speed and towing requirements not listed
AZT changes new 10 Driver + pasDriver side senger side 0 10 1000kg 1400kg Driver + pasDriver side senger side old 0
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European low speed Test Specifications Conclusions
A change of the barrier angle has a large effect on the bumper design Design change from old to new AZT 8,0 kg
Due to the 10 barrier angle, the barrier directly hits the crash box. The function of the crash box has increased, resulting in more energy taken over by the crash box. The function of the beam is solely to connect the left and the right side rail. The total dimension of the beam has decreased due to the loss of function. The test can be done on driver and passenger side - non symmetric design has no longer benefit Rear test only: The increase of mass leads to 40% more energy input
Old AZT 5,4 kg
New AZT
Remark: Thatcham and AZT are discussing to place a low speed test - similar to the IIHS criteria ECR 42 Pendulum test with only 4.0km/h for center and 2.5km/h for corner testing and only one pendulum layer has no big effect on the bumper design and is even not needed to release the car in the market.
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Page 11
Agenda Bumper Technology and Customer Portfolio The Hot Stamping Process - Material, Process, Performance, Design
Challenges in the bumper development for multi regional requirements :
- Europe (Changes, effect and conclusion) - North America (Changes, effect and conclusion)
www.autosteel.org
Page 12
Mismatch Example
Nissan Murano vs Micra Cut Away
Nissan Murano vs Micra - Impact
Source: Thatcham
Result: About 5.000$ repair cost on the Micra
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Page 13
North American low speed Test Specifications
30
ified d o m
Pendulum Tests CMVSS 215 USPart 581
Barrier 0 CMVSS 215 US Part 581 IIHS
Barrier 30- / Pole Test IIHS
Barrier height Test Speed Overlap New IIHS front and rear setup Full Frontal test Front corner Test 457 above ground 406 above ground 10km/h 5km/h center barrier in Y0 position 15% overlap to the car
Remark: High speed and towing requirements not listed
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Page 14
North American low speed Test Specifications
Conclusion (IIHS bumper test)
Don t mi ss p laye endulum r CM VSS overlap Stiff bumper is needed to reduce risk of under or over run. 215 test for 2 Due to this requirement, the weight will increase.
Shape and density of foam have a big influence on the system performance. Weak crash box/bumper connection can cause problems in deformation performance. Different results between full car models and component models possible. - movement of component cart could be more than 30mm in Z-direction. More than 60% coverage between bumper and barrier is necessary. Bumper front cover height proposal: between 110 and 130mm minimum. Complete car model to be taken for FE analysis or - add damping systems values to crash cart - add outer skin and foam to crash cart along with repair to the car - exact definition of position between bumper and barrier - Center of gravity, inertia tensor, axle position
