Crashworthiness Analysis of Automotive Frontal Bumper Materials

The crashworthiness of automotive frontal bumper systems plays a crucial role in improving vehicle safety by reducing impact forces transmitted to occupants during collisions. This research presents a comprehensive simulation-based analysis of bumper materials, including Aluminium Alloy (AA6061-T6), Mild Steel (AISI 1018), and Carbon Fibre Reinforced Polymer (CFRP), to assess their performance in terms of energy absorption, deformation, and stress distribution under frontal impact conditions. The study involves developing a detailed finite element model using ANSYS/Workbench to replicate a saloon car bumper subjected to a collision velocity of 15.56 m/s, consistent with NCAP test standards. Through rigorous computational analysis, the materials were compared based on crashworthiness indicators such as total deformation, equivalent (von Mises) stress, equivalent elastic strain, and specific energy absorption. The results revealed that the CFRP bumper exhibited superior crash performance, demonstrating high energy absorption capacity and reduced deformation with minimal structural mass. Aluminium provided a balanced performance with moderate strength and significant weight savings, while mild steel offered excellent strength and rigidity but at the expense of higher mass. Overall, the study concludes that selecting suitable materials is essential for optimizing safety, weight efficiency, and structural integrity in modern automotive bumper systems.