Failure analysis and design of a front bumper using finite element method along with durability and rig tests

Abstract

This work presents a case study that comprises the application of the Finite Element Method (FEM) to the design of a front bumper to predict possible failures caused by fatigue. Stress distribution and damage estimates were obtained by using FEM together with rig tests results. Vehicle durability tests were also performed, and geometric changes were proposed in the design of the component analysed based on the simulation results obtained from FEM. A good agreement between experimental data and FEM predictions was found. The case study and results demonstrate that time and cost can be reduced in the course of the product development phase in the automotive industry. FEM also can be used to support decision-making during the design phase of the product.