Seminar – I Report

on
‘Study of Design and Analysis of material for Automotive front Beam for low
speed impact’
By
Ms. Kadale Ketaki Rahul
Seat no.-17010
Under The Guidance of
Prof. Dr C.N.Kulkarni

Department of Mechanical Engineering

ZEAL EDUCATION SOCIETY’S
ZEAL COLLEGE OF ENGINEERING & RESEARCH
[2017-18]

ZEAL EDUCATION SOCIETY’S

ZEAL COLLEGE OF ENGINEERING & RESEARCH

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 CERTIFICATE
This is to certify that Ms. Kadale Ketaki Rahul. , has successfully completed the Seminar-I work entitled “Study
of Design and Analysis of material for Automotive front Beam for low speed impact’” under my supervision,
in the partial fulfilment of Master of Engineering – (Mechanical) (Design Engineering) of SavitribaiPhulePune
University , Pune.
Date :
Place: ZCOER, Pune

Prof. Dr. C. N. Kulkarni Dr. S. G. Dambhare

Guide Head of Department

External Examiner Seal Dr. A.M. Kate

Principal

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 ACKNOWLEDGEMENT
I take this opportunity to express my profound gratitude and deep regards to my guide Prof. Dr.C.N.Kulkarni
for his exemplary guidance, monitoring and constant encouragement throughout the course of this Seminar-I. The
blessing, help and guidance given by him time to time will carry me a long way in the journey of life on which I
am about to embark.

I also take this opportunity to express a deep sense of gratitude to our Head of Department, Dr. S. G.
Dambhare and Dr. A. M. Kate, Principal, Z.C.O.E.R. for their valuable guidance.

Thanking you,
Ms. Ketaki Kadale
Exam Seat No.

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 List Of Figures

Figure No. Name Of Figure Page No.

1 Isometric View Of impact layout
2 Magnesium, AL, Steel Bumper Deflection
3 Stress Vs Time(M220 Material)
4 Force Vs Time(M220 Material)
5 Frontal Impact System
6 Deformation Vs Time for Steel and Carbon Fiber Material
7 Energy Curve for Steel Bumper Beam system
8 Energy Curve For Carbon Fiber Bumper Beam system
9 Von Mises Stress Distribution in M220 Bumper Beam
10 Von Mises Stress Distribution in Carbon Fiber and Steel
Bumper Beam

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 Nomenclature

SAE Society Of Automotive Engineers

IIHS Insurance Institute Of Highway Safety
RCAR Research Council for Automotive Repair
ʋ Poisson’s Ratio
Ρ Density

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 CONTENTS
Title Page
Certificate
Acknowledgement
List Of Figures
Nomenclature
Content
Abstract

Sr. No. TITLE Page No.

1 INTRODUCTION
1.1 What is Bumper Beam system
1.2 Parts of Bumper Beam system
2 LITERATURE REVIEW
3 Theory Of BUMPER BEAM DESIGN CONSIDERATIONS
3.1 Theory
3.2 Manufacturing process
3.3 Material Section
3.4Impact Theory
4 STUDY OF FACTORS AFFECTING PERFOMANCE
OF BUMPER BEAM SYSTEM
4.1 Martensitic Steel
4.2 Carbon Fiber Bumper Beam design

5 RESULTS AND DISCUSSION

6 CONCLUSION

7 REFERENC

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 Abstract

In order to design front bumper beam two major factors are considered Internal energy absorbed
Automotive bumper beam is the key system in passenger cars to improve the safety of
automobiles during accidents , They protect hood, trunk, grill, cooling system as well as
headlamps and taillights.

Motive: This seminar topic focuses on study of design and materials used for Front Bumper
Beam system and different safety regulation standards followed in India and other countries like
America and Europe.

Method: In this seminar on ‘Study of Design and Analysis of material for Automotive front
Bumper Beam for low speed impact’ Results for energy absorbed by bumper beam and Force
and Deflection of bumper system are based on Ls-dyna simulation software method used.

by Bumper Beam system should be kept high using materials with high yield strength and high
modulus of elasticity. Maximum deformation should be kept in permissible limits

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1.INTRODUCTION
1.1 What is Bumper Beam System:
Automobile bumper subsystem is the frontal and rear structure of the vehicle that has the purpose of energy
absorption during low velocity impact. Usually, bumper subsystem consists of bumper transverse beam, stays,
impact - absorbing materials connected to the structural components (generally the bumper beam) and a cover,
that has both aesthetic and protection purposes. Among those elements, the bumper beam is the main structural
component; it is expected to be deformable enough to absorb the impact energy, in order to reduce the risks of
injury for pedestrians and other vulnerable road users, but, at the same time, it should also have sufficient strength
and stiffness to give place to small intrusion of the engine compartment and, therefore, to protect the nearby
vehicle components.

When accidents of frontal impact occur, the front bum-per system, which may to some extent protect the car body
and passengers, is the first part that receives the collision. This system is made up of three main parts. fascia,
energy absorber and bumper beam A non-structural component that reduces the air resistance, while the energy
absorber dissipates part of the kinetic energy during collision and the bumper beam is a structural component
which absorbs the low impact energy by bending resistance. Generally speaking, the bumper system mainly has
four functions. At first, it can protect the fender, radiator, engine hood, and lamps when low-speed impact happens
between the automobile and the other automobiles or barriers and transfer the impact energy to other components
of the automobile when high-speed impact occurs. Second, it should minimize the injury of the pedestrians while
the car hits pedestrians. Third, it may fulfill the car body aerodynamic requirements. Finally, it can decorate and
beautify the car body. Of the four functions, the first two, the focus of numerous studies, are particularly
significant

1.2 Parts of Bumper Beam system:

Bumper Beam System consist of following parts in it:
• Bumper Beam: It is the main part of Bumper Beam System
• Stay/ Crash Box RH/LH: It is attached with beam and Rail assembly
• Beam Plates: These are attached to Bumper Beam System

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2.LITERATURE REVIEW
Table 1:Literature Review

Sr. NO Title Of Journal Paper Author Publiation Year Of Publishing

1 The Applicability of Andersson R, Schedin SAE Technical 2002

Stainless Steel for Crash E Paper, 2002
Absorbing Components
2 Parametric study of Hosseinzadeh RM Composite 2005
automotive composite Structures 68
bumper beams subjected to (2005) 419–427,
low-velocity impacts” Elsevier Ltd.

3 Update of road safety Umar R University Putra 2005

status in Malaysia Malaysia
4 Design and analysis of Marzbanrad J M Thin-Walled 2009
automotive Structures
bumper beam in low speed 47(2009) 902–
frontal crashes”, 911, Elsevier
Thin-Walled Structure Ltd
5 Best-In-Class Global Bautista Garret SAE Technical 2009
Bumper Reinforcement Paper, 2009
Beam
6 The Evolving Use of Carrie M. Tamarell SAE Technical 2011
Advanced High Paper, 2011
-Strength Steels for
Automotive Applications”
7 Design and Analysis of an Mahesh Kumar V. Dange SAE Technical Mar-April 2015
Automotive Front Bumper Paper, 2015
Beam for Low Speed
Impact
8 Design E. S. Roopesh SAE Technical May 2015
and Analysis of an Paper, 2015
Automotive Frontal
Bumper Beam for Low-
Speed Crashes
9 Engineering Thermoplastic Evans D and Morgan T SAE Paper, 2016
Energy Absorbers for 2016.
Bumpers

Table 1: Literature Review Overview

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[1] Hosseinzadeh RM et.al In Parametric study of automotive composite bumper beams subjected to low-velocity
impacts” has observed structure, shape, and impact condition of glass mat thermoplastic (GMT) bumper by using
LS-DYNA pre solver and the results are compared with conventional metals like steel and aluminum. GMT
showed very good impact behavior compared with steel and aluminum, which all failed and showed
manufacturing difficulties due to strengthening ribs or weight increase due to use more dense
materials.

[2] Marzbanrad J M et. al In Design and analysis of automotive bumper beam in low speed frontal crashes”, Thin-
Walled Structure Author has has discussed that to increase crash performance in automotive vehicles it is
necessary to use new techniques such as use of energy absorption and materials. Components linked to crash
safety should transmit or absorb energy. The energy absorbing capability of a specific component is a combination
of geometry and material properties

[3] Bautista Garret et.al “ Best-In-Class Global Bumper Reinforcement Beam “Paper has detailed discussion
about best Design method for Automotive bumper Beam system as well as material to be used for
manufacturing of bumper beam system

[4] Carrie M. Tamarell et.al “The Evolving Use of Advanced High-Strength Steels for Automotive Applications”
contains vehicle manufacturers continue to become more aggressive with the styling of new vehicles, bumper
system technologies will be required to find new solutions that fit into the reduced package spaces while
continuing to meet the vehicle performance and cost requirements. It was suggested to introduce new and
innovative Expanded Polypropylene (EPP) foam technologies and techniques.

[5] Mahesh Kumar V. Dange et.al. “ Design and Analysis of an Automotive Front Bumper Beam for Low
Speed Impact” has performed The simulation of bumper beam is done under low-velocity impact as per the
standards of automotive stated in E.C.E. United Nations Agreement, Regulation no.42, 1994. The strength of
the bumper beam in elastic mode is investigated with energy absorption and impact force in maximum
deflection situation. Similar bumper beams made of different materials are simulated to determine the
deflection, impact force, stress distribution and energy-absorption behavior, these characteristics are compared
with each other to find best choice of material.

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[6] E.S Roopesh et.al “ Design and Analysis of an Automotive Frontal Bumper Beam for Low-Speed Crashes
a bumper beam is modeled and by considering three materials: high strength sheet molding compound (SMC),
glass mat thermoplastic (GMT) and aluminum are examined by impact test in order to measure the impact forces,
deflection, energy absorption and stress distribution behavior. The above parameters are compared to decide the
best selection of thickness, shape and material. In the end, we can say that the modeled SMC bumper can reduce
the stress distribution, deflection and impact force along with increase in the elastic strain energy. The studied
characteristics are represented in graphs at regular interval of time for comparison between different materials.
Furthermore, by suing SMC material we can achieve some other advantages like weight reduction, more
economical by using less cost composite materials and flexibility in manufacturing because of eliminating ribs.

2.1 Literature Gap Findings:

1) Various authors has studied Effect of Design and Material choice for performance of Bumper Beam System.
2) Comparison Between Different Material behavior and design for Indian Market need to be studied further.
3) For Carbon Fiber Composite materials study for recyclability needs to be done.

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 3. Theory Of BUMPER BEAM DESIGN CONSIDERATIONS

3.1 Theory:

• Packaging Space :Design of Bumper Beam depends on the packaging space provided by customer
Depending on the allotment of space Bumper Beam Manufacture decides the design and other parameters for
bumper beam

• Thickness : Thickness is the main variable that should be considered while designing Bumper Beam
system, It also contributes into the mass of overall vehicle and cost. For efficiency and speed it is required
to design low thickness high strength Bumper Beam

• Sweep :Bumper Beam Sweep provides some mechanical strength to the part and engineering performance
advantages to the bumper beam design

• Height/Weight Ratio: This factor also affects the performance of Bumper Beam design.

3.2Manufacturing process:

Manufacturing feasibility plays role while designing of bumper beam whether design for bumper beam is feasible
to manufacture or not that should be verified in manufacturing feasibility process. Roll forming is done for Steel
Bumper beam which is having one line stations for manufacturing Bumper Beam parts. Stamping is also used in
case of requirement of fine accuracy for production of bumper beam design. In case of manufacturing of
Aluminum Bumper Beam extrusion process is used. for acquiring desired sweep of bumper beam system
sweeping machine is used.

3.3 Vehicle safety Testing:

In India there are no strict regulations followed for Vehicle Crash safety, But in U.S.A , Canada, European
Union countries regulations for safety crash systems are strict and Bumper Beam system should be passed
through all Safety Test Mentioned for final mounting on vehicle and minimize the damage to the occupant and
Pedestrian Protection some safety Test are as mentioned below:

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IIHS: This Stands for Insurance Institute Of Highway Safety it has some centerline and Offset Front and Rear
Crash Impact Regulations. These regulations need to be completed by Beam manufacturers.

In North America (FMSS: Federal Motor Vehicle Safety Standards), Canada (CMVSS: Canadian Motor
Vehicle Safety Standards) and E.C.E. United Nations Agreement, Regulation No. 42, 1994[4].
This regulation is accepted by ARAI India
E.C.E. United Nations Agreement, Regulation no. 42, 1994 (1994). For these kinds of conditions, the passenger
car must be situated on a flat surface on releasing the break and gear and
impact test

3.4 Bumper Beam Material:

Bumper Beam Material is the vital factor which affects all other factors considered for manufacturing of bumper
beam design beam material will also affect manufacturing feasibility thickness consideration for Bumper Beam
and availability of material for manufacturing. The choice of the bumper beam material has a vital effect on the
impact performance of the vehicle. A proper selection can minimize the weight and get high
fuel efficiency without sacrificing the strength. It is said that 75% of fuel consumption directly relates to vehicle
weight. Lightweight composite materials provide opportunities for reducing vehicle weight ,thus increasing
fuel efficiency and reducing emission of harmful pollutants. On the condition of everything else remaining the
same, 6%–8% increase in fuel economy

3.5Impact Mechanism
important point to be noted is the type of impact that we obtain elastic or plastic impact. Negligible quantity of
energy will be losing in elastic impact in between two impacting bodies. Impact between two billiard balls can be
considered as an example. Considerable amount of energy dissipation will be taking place in plastic impact.
Impact between two automotive vehicles or at least between a rigid body and an automotive vehicle in which the
vehicle gets crumple on an impact. It is also an example of an elasto-plastic impact.
Since the impact between the front bumper and an impactor is nonlinear and transient analysis are involved, this
phenomenon can be very complicated in low-speed crashes. Therefore, the automobile manufacturers insist that
material failure or crash should not occur in bumper system while designing the bumper. Such that the total energy
will be conserved throughout the duration of impact. Here, the impactor is considered as rigid body and the font
bumper is made of composite and metallic materials, the load of the impact distributed irregularly along the
connecting area over the connecting region of the bumper beam. When the bumper is subjected to impact loading,

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it always undertakes a constant deformation Max . In the elastic impact, energy conservation principle is
considered here; kinetic energy is conserved before the impact and again converted to elastic energy. Kinetic
energy of automobile and the impactor during its maximum deflection can be expressed as follows:

4 STUDY OF FACTORS AFFECTING PERFOMANCE OF BUMPER BEAM SYSTEM

In order to understand the performance of Bumper Beam design depending on Design, Thickness and material
choice is studied in detailed Using Finite Element Modeling Method and using LS-Dyna as solver for this study
E.C.E United Nations Agreement, Regulation No. 42, 1994[4] selected. Design criteria selected as follows.
Maximum Von-Mises stress should be less than the yield strength

(Source SAE Journal Paper 2015)

Bumper Beam Material To find out the effect of bumper beam material on the impact behavior, two parameter
are studied here: modulus of elasticity and yield strength.5.1 Modulus of elasticity To study the effect
of modulus of elasticity three material are considered having their yield strength nearly equal and different
modulii of elasticity. Mechanical properties of the material are given in table 2
Table 2: Material Characteristics:
Parameters Of Steel Aluminum Alloy Magnesium Alloy
comparison 6060-T5
Strength (Mpa) 250 243 193
Density(kg/mm^3) 7850 2700 1800
Cost Less than Al Higher Less than Al
Deformation(mm) 51.92 65 87

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 (Source SAE Journal Paper 2015)
Above graph shows the comparison between deflection obtained for Bumper Beam using three different
materials. It is clear from the graph that steel stiffness is higher than AL and Magnesium alloy hence deflection
of steel bumper beam is less.
4.1 Martensitic Steel:
Martensitic steel having high modulus of elasticity and also it has high yield strength this type of steel are used
for the manufacturing of the bumper beam. Material property of the M220 given in
Next Table
Table 3:M220 Material Properties
Material E(Gpa) Y(Mpa) ʋ (Poisson’s Ρ (Denisyy) (Kg/mm3)
Ration)
M220 200 1350 0.3 7890

Figure 2: Stress(Mpa) Vs Time(S) Figure 3: Stress(Mpa) Vs Time

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 Figure 4: Force (N) Vs Time(S) (M220)
With bumper beam Material as M220 once again model is tested and the result are plot. The maximum
deformation of the bumper beam for M220 material is 28.10mm which is well below the permissible limit
40mm, also the maximum stress value is 1308.8 MPa which is less than the yield strength of the material
1350MPa. The maximum impact force is 33313.8N which is more than the aluminum alloys. Fig.4 shows that
the force absorbing capacity of the M220 material is higher than the all other material studied above

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 Fig 5: Front Impact Setup

(ARAI Front Impact Test Specifications)

(https://www.araiindia.com )
4.2 Carbon Fiber Bumper Beam Design:

Carbon fiber composites are called as the 21st century automotive materials. It has many advantages such as low
density, high strength, high modulus, high temperature resistance, corrosion resistance, self lubricating, good
conductivity/thermal performance, and low thermal expansion coefficient. Because of so many excellent
properties, the carbon fiber composites become very important raw materials in preparing vari-ous structural and
functional composites. Fiber-reinforced polymer composites possess several advantages over steel, the most
salient of which are their high strength-to-weight ratio and excellent corrosion resistance.
Carbon fiber composites can not only increase the strength of the structure but also decrease the weight of the
structure investigated the application of carbon fiber strengthened steel tubes to the frontal crush tubes of two
different passenger vehicles under frontal collisions. Substantial improvement, namely, the potential for vehicle
light-weighting, was accomplished. Such components had the potential to contribute to improvements in fuel
efficiency and emissions reductions in future passenger vehicles. Also studied the structure of carbon fiber
composite strengthening of thin steel passenger vehicle roof. Such fiber strengthening structure could gain
substantial increases in force resistance for steel tubes under both axial crushing and pure bending. And the
implications with regard to vehicle light-weighting were discussed. It was shown that fiber composite
strengthening of vehicle structure had the potential to contribute to higher roof
Carbon Fiber Reinforced Plastic(CFRP) is one of the example Carbon Fiber.

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However, relative to the materials such as steel or aluminum, the price of the carbon fiber composites is too
expensive to be widely used in the automobile manufacturing. carbon fiber composites, the commercial use of
carbon fiber composites automobiles will come true in the near future

4.3 Performance comparison Between Carbon Fiber and Steel Bumper Beam
In order to study the effect of the type of material on the impact behavior, the specifications of steel and car-bon
fiber composite were assigned to the bumper beam in separate impact simulations. Other characteristics of the
model such as fascia, foam, brackets, impactor, and so on remained constant The type of the carbon fiber
composite used in this study is T300/5208 whose density is 1.6 g/cm^3 and carbon content is 70%. The Poisson’s
ratio (y12) of the carbon fiber composite is 0.285. Table 3 shows its other mechanical parameters. The thickness
of the bumper beam is 6.6 mm

Fig.6 Deformation Vs Time for Steel and Carbon Fiber Material

(Source SAE Journal Paper 2016)
As we can see from comparison between deformation mode for Steel and Carbon Fiber Bumper Beam
Deformation for Carbon Fiber Bumper Beam is less than that of steel hence using carbon fiber bumper beam
impact on the surrounding parts of the vehicle will be less compared to Steel Bumper Beam system.

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 Fig 7 Energy Curve for Steel Bumper Beam system

Fig.8 Energy Curve For Carbon Fiber Bumper Beam system

(Source SAE Journal Paper 2016)

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By analyzing the change of energy which is obtained shown Figures 7 and 8 and the deformations from Figure 4,
the bumper system whose bumper beam is made by carbon fiber composite absorbs nearly the same kinetic
energy. But the maximum deformation of the carbon fiber composite bumper beam is lower than that of the steel
bumper beam. So through using the carbon fiber composite, the impact performance of the bumper beam is
improved.

5.RESULT AND DISCUSSION

Fig.9 Von Mises Stress Distribution in M220 Bumper Beam[1]

(Source SAE Journal Paper 2016)
Fig 9 shows the Von-Mises stress distribution in bumper beam. Maximum stress is induced at the
middle portion of the bumper beam as it is less than the yield stress of material so the bumper beam is safe.

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 Fig.10 Von Mises Stress Distribution for Carbon Composite and Steel Bumper Beam
(Source SAE Journal Paper 2016)
The von Mises stress distributions of carbon fiber composite bumper beam and steel bumper beam are
shown in Figure 10. According to Figure 10, at 0.072 s, the von Mises stress has the biggest value. The von
Mises stress of steel bumper beam is 1073 MPa, while the von Mises tress of carbon fiber composite
bumper beam is1466 MPa. Even though the stress value of carbon fiber composite bumper beam is bigger
than that of the steel bumper beam, the stress distribution of the carbon fiber composite is better than that of
Steel

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6. CONCLUSION
• In order to design the front bumper beam, two major factors considered. First the internal absorbed
energy by the bumper beams should be kept high by using material having high yield strength and high
modulus of elasticity.
• In the second place, any plastic deformation of the bumper beam should be avoided as much as possible
in low-speed mode.
• Maximum deformation of bumper beam kept within the acceptable limit. The maximum stress of the
bumper is also below the yield stress of material
.
• From the study of passenger it is clear that if bumper is safe for with passenger then it is definitely safe
for without passenger
• From this study it is clear that High Strength Steel M220 Material has better Performance than
Conventional Steel and Aluminum Alloy
• Use of carbon Fiber Bumper Beam has advantageous in Light weighting, Low deformation and high
strength compared to Steel and Aluminum Bumper Beam system.
• As per market below is the table describing review for Prize of the bumper beam
Steel 13.51-14.51(Rs.)
M220 Steel 96.61-97(Rs)
Magnesium Alloy 100.67(Rs)
Aluminum Alloy 337-340(Rs)
Carbon Fiber Reinforced Plastic 1148-1149(Rs)

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7. REFERENCES

• 1)Umar R.. Update of road safety status in Malaysia. University Putra Malaysia. 2005.
• 2)Hosseinzadeh RM, Shokrieh M, and Lessard LB, “Parametric study of automotive composite
bumper beams subjected to lowvelocity impacts”, Composite Structures 68 (2005) 419–427,
Elsevier Ltd.
• 3)Marzbanrad J M, Alijanpour M, and Kiasat MS, “Design and analysis of automotive bumper
beam in low speed frontal crashes”, Thin-Walled Structures 47(2009) 902–911, Elsevier Ltd.
• 4)United Nations agreement, Uniform provisions concerning the approval of vehicles with
regards to their front and rear protective devices (bumpers, etc.), E.C.E., 1994.
• 5)Andersson R, Schedin E, Magnusson C, Ocklund J, “The Applicability of Stainless Steel for
Crash Absorbing Components”, SAE Technical Paper, 2002.
• 6)Evans D and Morgan T, “Engineering Thermoplastic Energy Absorbers for Bumpers”, SAE
Paper, 2016.
• Websites:
• [1] www.ansys.com
• [2] http://www.ispat.com
• [3] https://www.araiindia.com
• [4] http://www.nhtsa.dot.gov/cars/testing/procedures/TP-581-01.pdf
• [5] http://www.autooutlet.es/MS0101330

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