International Journal of Advancements in Research & Technology, Volume 5, Issue 4, April-2016
ISSN 2278-7763
34
DESIGN AND ASSESMENT OF A FIBRE GLASS LEAF-SPRING
REINFORCEMENT ON CARBON FIBER POLY-ETHER-IMIDE
(PEI) BUMPER’S IMPACT PERFORMANCE
1
ASHA SATURDAY,2 EJEHSON PHILIP SULE,3 EZEONWUMELU OGECHUKWU, 4SAMUEL
WADZANI GADZAMA, 5OKOYE C. BENJAMINE,
1
ashiga4oxide@yahoo.com,2ejehsonadole@yahoo.com,3oscargulfecho@yahoo.com.,4swadzani
@yahoo.com
1,2,3,4,&5
Scientific Equipment Development Institute SEDI,P. O .BOX 3205,Enugu ,Enugu
State,Nigeria
ABSTRACT
The automotive industry has been very competitive as far as its design and material usage are
concerned. The automotive industries face greater market pressure on how to develop high
quality products at lower cost, reduced weight in order to improve fuel efficiency and cost, this
aesthetics consideration had led the automotive engineers not to focus on car’s delicate
component and engine besides the users. Good bumper design like Car body shell stiffness can
help to protect the occupants of a car. Thus , this work aims to design and analyzed impact
performance on absorption of impact energy during a low and high speed collision, stress
distribution ,stiffness and rate of deflection a carbon fibre PEI- Poly-Ether-Imide fibre glass
leaf spring reinforced bumper to protect delicate car component ,occupants and pedestrian. The
bumper performance is enhanced by the leaf spring fibre glass reinforcement in PEI bumper
which lowered the deflection or deformation on impact.
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KEY WORDS: fibre glass Leaf spring reinforcement, PEI bumper ,impact performance,
collision.
INTRODUCTION
These numbers call for the necessity to
Car accidents are happening every day, nor
improve the safety of automobiles during
of these had favoured neither the car delicate
accidents. As a result, most present-day
systems nor the users. Most drivers are
automobiles have at least safety belts with
convinced
retractors and airbags besides the bumpers
that
they can
avoid
such
instantaneous situations by jumping out or
that
swerving the car. Nevertheless, many of
collision. An automobile's bumper is the
thousand
of
front-most or rear-most part, ostensibly
thousands to million wounded every year.
designed to allow the car to sustain an
are
dead
and
Copyright © 2016 SciResPub.
hundreds
received
this
sudden
impact
on
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International Journal of Advancements in Research & Technology, Volume 5, Issue 4, April-2016
ISSN 2278-7763
35
without damage to the vehicle's
The bumper like the entire body of
safety systems. They are not capable of
a car is made of plated steel as it
reducing injury to vehicle occupants in
was used,
high-speed
well, as it was very strong in a crash,
impact
impacts, but are increasingly
being designed to mitigate injury
This material worked
to
but it was very heavy and dented
But this is
performance as it does not return to
against the opinions and minds of users
its normal position after impact. As
,common men and women including the
car engine design has improved, steel
engineers who wished bumpers should have
bumpers
the ability to protect the vehicle occupants
disappeared
and delicate parts like the convector
classic cars. Reducing the weight of
(radiator),and engine as a system. Bumper
the car for fuel economy makes the
systems usually include a reinforcement
use of steel bumper not in vogue.
pedestrians struck by cars.[1]
have
pretty
much
for anything
except
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bar plus energy-absorbing material, such
as
polypropylene
foam. The
more a
bumper extends from a car body, when
other factors remain equal to the more it
absorbs
crash
energy
and
reduces
damage. The majority of modern plastic
car bumper system fascia’s are made of
thermoplastic
olefins
(TPOs),
II.
Plastic bumper
polycarbonates, polyesters, polypropylene,
Most modern cars use a reinforced
polyurethanes, polyamides, or blends of
thermoplastic bumper, as they are
these with, for instance, glass fibers, for
cheap to manufacture, easy to fit
strength and structural rigidity. The level of
and
impact is a function of speed of the vehicle.
crash.
Hence the momentum of cars is dependent
on speed at that particular time.
III.
absorb more energy during a
Body kit bumper
Modified cars often now have a
full body kit rather than just a front
TYPES OF BUMPERS
I.
Steel bumper
Copyright © 2016 SciResPub.
and rear bumper. These kits act as a
skirt around the entire body of the
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IV.
36
car and improve performance by
thermoplastic
reducing the amount of air flowing
polycarbonates, polyesters, polypropylene,
underneath
so
polyurethanes, polyamides, or blends of
reducing drag. Hence, the bumper
these with, for instance, glass fibers, for
forms an integral part of this body
strength and structural rigidity. The use
kit.
of plastic in auto bumpers and fascias gives
Carbon fiber bumper
designers a tremendous amount of freedom
Carbon fiber body work is normally
when it comes to styling a prototype
the thing of super-cars, but many car
vehicle, or improving an existing model.
companies,
specialist
Plastic bumpers contain reinforcements that
modifiers, are starting to use it for
allow them to be as impact-resistant as
replacement body part on everyday
metals
while
being
cars.
replace
than
their
the
car
and
and
(TPOs),
less expensive
metal
to
equivalents.
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However the cost of repair of damaged
plastic or composite bumper is high, even if
it is amended it lost its beauty, because the
technology is not available in this part of
country-Nigeria.
olefins
This
is
one
of
the
Plastic car bumpers generally expand at the
same rate as metal bumpers under normal
driving
temperatures and do not usually
require special fixtures to keep them in
place.
numerous disadvantages of the modern cars
The replacement of metal in bumper to
imported into the country
reduce the weight of the vehicle, reduce
Replacing one involves a lot of searching for
scrap cars or having one specially made.
foam.
Better
bumpers
often
have
hydraulic shock absorbers instead of, or in
addition to, the foam. Today's plastic auto
bumpers
and
aesthetically
fascia
pleasing,
systems are
while
offering
advantages to both designers and drivers.
The
majority
bumper
system
of
modern plastic
fascias
Copyright © 2016 SciResPub.
are
made
car
of
cost and improve petrol consumption has
follow several stages mostly directed at
the
bumper
fascia
and
polypropylene,
improving
polyurethane,
thermoplastics, elastomers, PC/ABS and
PC/PBT blends. Bumpers fascias are hardly
3 mm thick and the key physical properties
are for
Today,
flexibility and shock resistance.
the
mostlyused
polypropylenes,
due
to
materials
are
compromise
between cost and mechanical properties.
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Other thermoplastics used for fascias have
the
mainly
particles by developing an alloy at the
been
alloys-based
PBT
polycarbonate, which have
and
been used
polypropylene
surface.
This
and
was
elastomers
obtained
by
mainly in Europe by top car models of
optimization of the molecular structure of
BMWand Mercedes. Polyurethane is also
both components Basically,
used in bumpers where flexibility has the
important mechanical properties of a car
advantage of avoiding deformation. For
bumper are strength and toughness as
example, a bumper which is made of
well. Toughness is a mechanical term
polyurethane will roll back into its initial
that is used in several contexts. Loosely
shape after small shock or collision where
speaking, it is a measure of the ability of
the speed is usually less than 5 km/h. It is
materials to absorb energy before it tends
very convenient and avoids costly repair.
to fracture. Fracturetoughness is a property
For Nissan, they developed an integrated
indicative of a material’s resistance to
the
most
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lightweight bumper system for their vehicle
fracture when a crackis present. For a
using higher modulus polypropylene. The
material to be tough, it must display both
usage of this material precluded the need
high strength and ductility.
for the steel reinforcement that up until
then was necessary for the polypropylene
STATEMENT OF THE PROBLEM
bumper. In order to obtain the required
Luxury cars, very expensive not only to
material properties which is
high
in
purchase but also to repair. Bumper designs
strength,
an
of Modern front-end styling that can either
advanced compounding technology was
slide under the bumpers or vehicles they
applied to improve the existing mineral
strike or that simply do not have enough
filled polypropylene bumper material. The
room to absorb the energy of speed crash.
higher
by
The bars underneath bumper covers often
advanced in compounding technologies
are not up to absorbing the energy. The bars
which minimized the filler function and
may not be big enough to provide much
achieved in higher dispersion level for
protection from damage or they may be
higher loading for fine particulate filler.
too flimsy to absorb much energy. Hence
Impact
design
modulus
and
modulus
strength
impact
was
was
achieved
increased
by
of
a
glass
fibre
leaf
spring
improving the interfacial strength between
Copyright © 2016 SciResPub.
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reinforcement PEI bumper is design and
on the glass fibre leaf spring reinforced PEI
analysed.
bumper due to the collision .To mitigate the
AIMS AND OBJECTIVES
degree of damage to passengers caused by
automobile collisions, a PEI leaf spring
This work is to determine energy absorption
damper reinforced bumper was desiged its
structure that will . In order to achieve
effectiveness in impact energy attenuation
the main objective, the analysis of stress
and impact performance.
distribution ,stiffness and rate of deflection
COMMON BUMPER SYSTEMS
The bumper systems are are detailed
2.
Plastic fascia, reinforcing beam and
energy absorption system
diagrammatically as follows;
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1. Plastic fascia and reinforcing beam
system
C
a.
d.
b.
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e.
METHODOLOGY
Properties of these materials using solid
The 3D model of bumper reinforcement is
made in SOLID WORKS 2014 After this
works material data
BASE MATERIAL –PEI
the same model is imported in to ANSYS
workbench
for impact analysis and total
deformation is observed. We applied high
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Velocity condition for impact
,90,100,110,120,130,140,150
at
80
km/hr and
assumed car weight of mass 1000 kg. In
100% frontal impact force component is
perpendicular to the bumper. by using
Newtons second law, we calculated force F
SOURCE:Solid Works 2013c
value. This point force applied centrally on
FOR PEI (30% CARBON FIBRE)
Bumper beam
ANALYSIS
The analysis is done with models designed
with SOLID Works 2014c with controlled
test using PEI material only. And the fibre
glass leaf spring reinforced PEI Bumper.
MATERIALS COMPOSITION
1. PEI
Culled from GRANTA 2011(Copyright ©
2011, Granta Design, Cambridge, UK)
2. Fibre glass
Copyright © 2016 SciResPub.
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The kinetic Energy of a moving Car is equal
REINFORCED MATERIAL –S –GRADE
to the energy to cause deformation.
𝐾𝐸 = 1�2 𝑚𝑉 2
FIBRE GLASS
[1]
Where 𝐾𝐸 is kinetic energy possessed by the
car, 𝑚 is the mass of the car, and V is the
speed of the car.
Work Done on deformation of the bumper
𝑊𝐾 = 𝐹𝑑
[2]
𝐾𝐸 = 𝑊𝐾
[3]
Hence ,the conservation of energy ,
SOURCE:Solid Works 2013c
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For S –grade Fibre Glass properties
1� 𝑚𝑉 2 = 𝐹𝑑
2
[4]
The speed is in kilometers per hour ,hence
speed in meter per second becomes
𝑉 (𝑚⁄𝑠𝑒𝑐) =
𝑉(𝐾𝑚 ⁄ℎ𝑟 )∗1000
3600
[5]
The force required for the deformation is
analytically equal to the impact force as well
as the centripetal force. Hence, Hooke’s law;
Culled from GRANTA 2011(Copyright ©
2011, Granta Design, Cambridge, UK)
𝐹 = 𝐾𝑒 [6]
For elastic body like the bumper that is
From the law of conservation of energy
,energy possessed by the a car during motion
must be equal to energy to stop it from
subject to deformation on collision
Where, e is extension and K,Elastic constant
or stiffness of the reinforced bumper body.
moving . Hence ,from Newton’s third law of
motion ,’ To every action, there is equall and
This could be written as equation
opposite reaction’.
Copyright © 2016 SciResPub.
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𝐹𝐼𝑀𝑃 = 𝑆𝛿 = 𝐾𝛿
41
Fig,1.3 D model
[7]
Where
𝑒=𝛿 = extension
as
elastic
deformation(deflection)(m)
𝐾 = 𝑆=Stiffness of the bumper (N/m)
MODELING
ASSUMPTIONS
In the analysis certain assumptions were
made and are as stated as follows:
i.
The leaf spring is assumed to be
fixed at the eyes.
ii.
The material composition was
selected to be AISI316 Annealed stainless
steel
bar(SS).
iii.
Displacement x (m) is taking
considering
first impact load and not
rebounce.
iv.
There is no friction between the bod
under test and the applied load .
v.
PEI material and leaf spring material
are isentropic on their individual basis.
vi.
weight is contant at all speed.
a.
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b.
fig 2, a and b 3 D Mesh model
MODELS
Fig 3.
PEI deflection
@ a particular
speed
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Fig 6. PEI von mises stress @ a mean
speed
Fig 4.
PEI Von Mises stress
@ a
REINFORCEMENT
particular speed
An
average
speed
of
115𝐾𝑚ℎ𝑟 −1 (31.94m𝑠𝑒𝑐 −1 ) will give a
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maximum deformation of 63.1045 mm
Fig 7.3 D model of fibre glass leaf spring
reinforcement
Fig 5. PEI deflection @ a mean speed
Fig 8.3 D model of fibre glass leaf spring
reinforcement mesh
Copyright © 2016 SciResPub.
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Fig 9.3 D model of fibre glass leaf spring
reinforcement von misses stress @ a
43
Fig 11.3 D model of fibre glass leaf spring
reinforcement deflection @ mean speed
speed
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Fig 12.3 D model of fibre glass leaf spring
reinforcement von misses stress @ mean
Fig10.3 D model of fibre glass leaf spring
speed
reinforcement deflection @ a speed
MEAN VALUES
MESH DETAILS
Table 1. MESH PROPERTIES
Total Nodes
Copyright © 2016 SciResPub.
Aspect
Jacobian
Ratio
Points
16537
10.822
4 Points
Total
Mesh Type
Element Size
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Elements
7728
44
Solid Mesh
25.8514 mm
TABLE 2.VALUES FROMTHE SIMULATION
The average weight of the car assumed, M =300kg
Distant travelled on the said speed, d=100m
s/n
Car Speed,
Impact
V(𝐾𝑚ℎ−1 )
Max
𝛿,(mm)
4
110
5
120
6
130
7
140
8
150
Mean,(𝑥̅ )
115
30.56
REINFORCED BUMPER
Copyright © 2016 SciResPub.
29.3723
0
18.598
37.1942
0
26.4406
45.8944
0
32.6254
55.532
0
39.4765
66.088
0
46.9805
77.5615
0
55.1368
89.953
0
63.9456
103.262
0
73.407
63.1045
0
44.8596
937.50
100
27.78
(Mpa)
740.74
90
25.00
3
Node: 130
stress
8544
V(𝑚𝑆 −1 )
22.22
2
𝛿,(m)
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80
Von
Force,F(N) Deflection, Deflection, Mises
Node:
1
Min
1157.41
1400.46
33.33
1666.67
36.11
1956.02
38.89
2268.52
41.67
2604.17
31.94
1591.43
MODEL PROPERTIES
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Mass:
18.4541 kg
Total Nodes
Volume:
0.0145308 m^3
Density:
1270 kg/m^3
Weight:
180.85 N
45
Aspect
Jacobian
Ratio
Points
18406
14.042
4 Points
Total
Mesh Type
Element Size
Solid Mesh
29.7989 mm
Elements
MESH DETAILS
8661
TABLE 3. MESH PROPERTIES
TABLE 4.VALUES FROMTHE SIMULATION
The average weight of the car assumed, M =300kg
Distant travelled on the said speed, d=100m
s/n
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Car Speed,
Impact
V(𝐾𝑚ℎ−1 )
Max
Force,F(N) Deflection,
𝛿,(mm)
Node:
1
80
2
90
25.00
3
100
4
110
5
120
6
130
7
140
Deflection, Mises
𝛿,(m)
Node: 121
stress
(Mpa)
3.53059
0
3.32523
4.46841
0
4.2085
5.51656
0
5.19569
6.67501
0
6.28676
7.94385
0
7.48179
0
8.7807
0
10.1835
740.74
937.50
27.78
1157.41
30.56
1400.46
33.33
1666.67
9.32298
36.11
1956.02
38.89
2268.52
Copyright © 2016 SciResPub.
Von
14715
V(𝑚𝑆 −1 )
22.22
Min
10.8125
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8
150
Mean,(𝑥̅ )
115
41.67
2604.17
31.94
1591.43
46
12.4123
0
11.6903
7.58524
0
7.14403
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GRAPH
Effect of impact Force
compare results at a glance effect of the
fibre glass leaf spring reinforcement on the
PEI bumper
a. WITHOUT REINFORCEMENT
Maximum Deflection of
bumper ,mm
The graphs are detailed to show and
120
100
80
60
40
20
0
y = 0.0396x + 0.0094
R² = 1
0
1000
2000
3000
Impact Force ,N
Copyright © 2016 SciResPub.
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Fig 13. Effect of impact force on bumper
Effect of Impact Force
Maximum Deflection,mm
Deflection without reinforcement
Von Mises stress (Mpa
Stress built up as a result
of impact
80
y = 0.0288x - 1.3089
R² = 0.9987
60
40
47
15
y = 0.0048x - 3E-05
R² = 1
10
5
0
0
1000
2000
3000
Impact Force,N
20
0
0
1000
2000
3000
Impact Force,N
Fig 16. Effect of impact force on bumper
Deflection with reinforcement
Stress built up on
bumper
Fig14. Effect of impact force on bumper
Von Mises stress without reinforcement
Von Mises Stress,Mpa
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ximum Deflection ,mm
Effect of car speed on
bumper
150
y = 1.0555x - 58.27
R² = 0.9925
100
50
50
100
y = 0.0045x + 5E-06
R² = 1
10
5
0
0
1000
2000
3000
Impact Force ,N
0
0
15
150
Car Speed Km/hr
20
Fig 17 Effect of impact force on bumper
Von Mises Stress with reinforcement
Fig 15. Effect of Car speed on bumper
Deflection without reinforcement
REINFORCED BUMPER
Copyright © 2016 SciResPub.
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Maximum deflection,mm
Effect of car speed
15
y = 0.1269x - 7.0061
R² = 0.9925
10
5
0
0
50
100
150
200
Car Speed km/hr
Fig 18. Effect of Car speed on bumper
Fig20. Rate of Deflection with time of
Deflection with reinforcement
collision
Car Speed,km/hr
Effect of car Speed
200
on
the
bumper
without
reinforcement
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y = 0.0373x + 55.666
R² = 0.9925
150
100
50
0
0
1000
2000
3000
Impact Force,N
Fig 19. Effect of Car speed on impact
force on the bumper with reinforcement
Fig 21. Rate of Deflection with time of
collision on the bumper reinforcement
DISCUSSION
Bumper deformation becomes necessary to
consider on collision with a pedestrian, or an
obstacle. Hence ,damage caused to the
bumper ,car’s delicate parts are greatly
considered besides weight reduction and
impact on pedestrians that do not make us
Copyright © 2016 SciResPub.
use steel leaf spring reinforcement.
The
models results on tables ( 2) , and
(4)
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49
revealed that reinforcing the PEI bumper
The bumper dynamic simulation on impact
with a material with high yield strength will
analysis for a fibre glass leaf spring
help to reducing the deformation of the
reinforced PEI bumper performance could
bumper. Using
be
fibre glass and PEI
used
on
further
bumper
design.
composite matrix may not give the results as
Simulation results reveal good performance
performed by the ingenuity of incorporating
as low deformation was achieved with
shock absorbing ability of leaf spring, hence
reinforcement compared with the with large
a fibre glass leaf spring was conceptualized
deformation without reinforcement. it can be
in the design. Graphical representation from
concluded that the bumper is an important
the results in the tables ( 2) , and (4) show
member of an automobile from the safety
at a glance the effect of the fibre glass leaf
point
spring
components. Thus analysis of bumper
reinforcement
on
the
impact
performance of the reinforced PEI bumper.
The
spread
will
of
help
view of the car’s delicate
to
increase
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or
propagation
of
the
considered
to
replace
the
the
safety
existing
deformation with the collision simulation
materials like steels and general fiber. The
time in fig. (20) and (21)was shown to x-ray
project data can be used for best bumper
collision that will involve drag before
designs
stoppage. However, other conditions that
material,weight reduction ,and performace
could improve the bumper reinforcement
point of view. Impact loading parameters
could also be investigated-thickness of the
were
bumper, and geometric parameters of the
kinectic energy possessed at a distant of
fibre glass leaf spring. A correlation work on
100m.
parametric
analysis
of
the
effect
of
geometrical parameters on the performance
of modern
vehicles
from
evaluated for varying speeds and
FUTURE WORK
of a master leaf spring was done by Haruna
The experimental impact test at various
M S, Enebe O ., Asha .S
2015 el ta
energy on this model should be done for an
revealed that thickness, radius of curvature,
onward assurance of the performance and
span ,and width of leaf spring affects its
acceptability by the automotive industries.
performance .
Fatigue test could be done as well as a
CONCLUSION
Copyright © 2016 SciResPub.
comparative work should be done on this
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