Geometrical optimization of bumper beam profile made of pultruded composite by numerical simulation

In addition to their high specific strength and specific stiffness composite materials possess high energy absorption capability, that makes them an interesting alternative material for developing automotive safety component, when to combine weight saving and crashworthiness is highly desirable. In this work E-Glass/epoxy pultruded bumper beam is considered and its energy absorption capability is compared with steel and E-Glass/epoxy fabric composite. Furthermore, low velocity impact finite element simulations are performed using ABAQUS, in order to optimize beam section profile and beam curvature for crashworthiness. Results show that, pultruded bumper beam has comparable energy absorption capability with respect to the steel normal production solution. The new composite solution, after appropriate optimization of bumper beam section profile and beam curvature, exhibits yields improved energy absorption characteristics; the development of progressive failure mode leads to lower mean crash load and almost constant force diagram whose value is close to the maximum peak load.