Abstract
IIHS has been changed bumper testing method to reflect real vehicle-to-vehicle collisions and the kinds and amounts of damage they cause. The first test results by IIHS showed most car bumpers don't work well in low-speed crashes. Sonata and Optima had relatively good performance in full rear test and corner rear test, respectively. We need new design concepts which are different from existing Bumper Beam deign concepts due to the impact energy and procedures are totally different. We derived new concept for IIHS test from current two bumpers. We reflect new design concept for IIHS performance enhancements from test results of current vehicle. We changed weight distribution of beam for full barrier and extended beam for corner barrier test. The bench test with modified design showed improved performance. Base model of bumper which was incorporated Old car test results was optimized by DFSS method using L18 orthogonal array., We chose thickness of each section as control factor and vehicle weight and speed as noise factor. We achieved weight reduction of beam even though vehicle weight was increased and beam length was extended, Also, quality cost reduction is expected in the future since S/N ratio increases from existing model. In conclusion, we designed new beam which satisfy IIHS test with reduced weight.
Keywords: New IIHS, Bumper Beam, Optimization, DFSS