Roll forming simulation for automotive bumper fixing / Faizarul Akmal Jamaludin

Project paper (Bachelor of Mechanical Engineering with Automotive) -- Universiti Malaysia Pahang - 2008

The bumper beam today is generally made of steel via stamping. The structural and Complexity potential of such parts is very high but investments and variable costs are significant. A process offering an economic and flexible alternative is roll forming. In this paper, a simulation has been done in order to compare between roll forming and stamping bumper beam. CAD softwares have been used for the simulation and analysis which are Solidwork 2005 and finite element analysis software Algor version 21. The bumper beams have been design in Solidwork and the Algor has been used to make stress analysis to the bumper beams. The static stress with linear material model has been applied to the both bumper beams that are from stamping and roll forming for comparison. The surface loads that have been applied to the bumper beams are calculated from the velocity of Gen-2 car at 80km/h to 120km/h. From the analysis the maximum stress for stamping bumper beam is 282.82MPa and 243.29MPa for roll forming bumper beam. After that, the analysis about costs to produce each bumper beam has been done. The costs that have been considered for this thesis are costs from man, machines and materials. From the calculation the production of stamping bumper beam need cost about RM 26 032 400 and for the roll forming bumper beam just need RM 3 010 600 for the production cost. As a conclusion, from this thesis roll forming bumper beam has more advantages compare to stamping bumper beam.