FEA Simulation Of Vehicle Bumper On Sweeping Process

Bumper is an important component in the whole vehicle body. It has a great effect on the safety protection feature of vehicles, the appearance and modeling effect, the aerodynamics function and so on. To satisfy the current requirements for the light weight of automobiles, ultra-high strength steel bumper is on the increasing demand. Because of the lack of the theoretical research data related to on-line sweeping for bumper made with ultra-high strength steel and trial and error method is used to the bumper production. At the same time, the design and requirements are always vary so much, so we need to devise a set of means for sweeping technological parameters in order to reduce the experimental work as much as possible and to provide appropriate support for bumper manufacturers.This issue focused on the practical problem that a sort of bumper with some design requirements encountered during the period of on-line sweeping after cold roll forming process, such as the control of bending radius and some defects of the bumper. After the bending scheme and technological parameters were determined, the rise of roller was calculated through large deflection plastic theory, and according to the simulation of sweeping process for the bumper by using Finite Element analysis software, the paper discussed the curvature, the strain and stress and defects after the sweeping period, and then the bending radius was obtained and evaluated by the curve fitting function of commercial mathematical software MATLAB for spots on the neutral layer of the bumper. The simulation of sweeping was made for three different rising distances of rollers, the stress and strain and defects arising from the situation were analyzed, the bending radius was fitted, and what's more, the relationship between the bending radius and the rising distance of the roller were summed up. In order to reduce the defects occurred during the process, certain modifications were made for the original plan of sweeping on the basic analysis of sweeping results, and by applying the new one it can lessen the surface defects and the stress, so it will meet the design requirements better.In short, all the exploratory research mentioned above are helpful to the actual production when using cold roll forming method and on-line sweeping process, and it is of certain reference value.