Bumper is one of the most important parts in passenger cars for which the material and structure should be considered in order to reduce the impact of collision. Since suitable impact strength is the main expectation for such a structure, the authors survey the variables that directly give impact characteristics and wished for easily achievable modifications resulting from impact modeling on commercial bumpers. Many researchers have studied that accident always occurs in front side. The impressed the authors to study and analyses the component related to frontal crash and therefore, the authors selected bumper. Aim of the project work is reduce the effort of car bumper by introducing honey comb structure instead of regular rubber block as impact block.

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International Journal of Research and Innovation (IJRI)
International Journal of Research and Innovation (IJRI)
REDUCTION OF IMPACT EFFECT ON CAR BUMPER USING
MEMORY SHAPE ALLOY PADS.
M.Arun Kumar, 1
, Y Anil Reddy2
, Godi Subba Rao3
,
1 Research Scholar, Department of Mechanical Engineering, Hyderabad Institute of Technology and Management, Hyderabad, India
2 Assistant professor, Department of Mechanical Engineering, Hyderabad Institute of Technology and Management,Hyderabad, India
3 professor, Department of Mechanical Engineering, Hyderabad Institute of Technology and Management, Hyderabad, India
*Corresponding Author:
M.Arun Kumar,
Research Scholar, Department of Mechanical Engineering, Hy-
derabad Institute of Technology and Management, Hyderabad,
India
Published: July 04, 2015
Review Type: peer reviewed
Volume: I, Issue : IV
Citation: M.Arun Kumar, Research Scholar (2015)
REDUCTION OF IMPACT EFFECT ON CAR BUMPER
USING MEMORY SHAPE ALLOY PADS.
PROBLEM DESCRIPTION AND METHODOLOGY
Car bumper is used for the protection of passengers, gen-
erally steel or impact grade plastics are used as bumper
material along with rubber pads between chassis and
bumper.
As per the previous research passenger’s protection can
be increased up to 34% by increasing bumper thickness.
But the percentage of passenger safety is not satisfactory
even after modifications.
This is an attempt to increase the passenger’s safety by
implementing honey comb structure and (NITINOL) mem-
ory shape alloy which is used as damper strings.
The following process will be followed to increase passen-
ger’s safety.
1)Parametric model will be created to conduct analysis.
2)Structural analysis will be conducted on normal model
to evaluate the results ( for comparison purpose).
3)Analysis will be carried out by changing bumper materi-
als.
4)Honey comb structure pad with rubber and memory
shape alloy will be analyzed to determine impact condi-
tions.
INTRODUCTION TO BUMPER OF A CAR
An automobile's bumper is the front-most or rear-most
part, ostensibly designed to allow the car to sustain an
impact without damage to the vehicle's safety systems.
They are not capable of reducing injury to vehicle occu-
pants in high-speed impacts, but are increasingly being
designed to mitigate injury to pedestrians struck by cars.
First standards
In 1971, the U.S. National Highway Traffic Safety Admin-
istration (NHTSA) issued the country's first regulation ap-
plicable to passenger car bumpers. Federal Motor Vehicle
Safety Standard No. 215 (FMVSS 215), "Exterior Protec-
tion," took effect on 1 September 1972 — when most au-
tomakers would begin producing their model year 1973
vehicles. The standard prohibited functional damage to
specified safety-related components such as headlamps
and fuel system components when the vehicle is subject-
ed to barrier crash tests at 5 miles per hour (8 km/h) for
front and 2.5 miles per hour (4 km/h) for rear bumper
systems. In October 1972, the U.S. Congress enacted the
Motor Vehicle Information and Cost Saving Act (MVICS),
which required NHTSA to issue a bumper standard that
yields the "maximum feasible reduction of cost to the
public and to the consumer". Factors considered includ-
ed the costs and benefits of implementation, the stand-
ard's effect on insurance costs and legal fees, savings in
consumer time and inconvenience, and health and safety
considerations.
The 1973 model year passenger cars sold in the U.S. used
Abstract
Bumper is one of the most important parts in passenger cars for which the material and structure should
be considered in order to reduce the impact of collision. Since suitable impact strength is the main expec-
tation for such a structure, the authors survey the variables that directly give impact characteristics and
wished for easily achievable modifications resulting from impact modeling on commercial bumpers. Many
researchers have studied that accident always occurs in front side. The impressed the authors to study
and analyses the component related to frontal crash and therefore, the authors selected bumper.
Aim of the project work is reduce the effort of car bumper by introducing honey comb structure instead of
regular rubber block as impact block.
•Initially data collection and literature survey will be done to understand the problem and rectification
methodology.
•A parametric model and design will be prepared using reverse engineering process.
•Structural analysis will be carryout on regular and with honey comb structured damper pad with rubber
and NITINOL material as a damper element.
•Impact analysis will be carryout on bumper with honey comb structured damper pad.
•Comparison will be done between result of traditional and honey comb structured bumper pad.
•Graphs and tables will be prepared for easy understanding and comparison.
1401-1402

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International Journal of Research and Innovation (IJRI)
a variety designs. They ranged from non-dynamic ver-
sions with solid rubber guards, to "recoverable" designs
with oil and nitrogen filled telescoping shock-absorbers.
The standards were further beefed up for the 1974 model
year passenger cars with standardized height front and
rear bumpers that could take angle impacts at 5-mile-per-
hour (8 km/h) with no damage to the car's lights, safety
equipment, and engine. This often meant additional over-
all vehicle length, as well as new front and rear designs to
incorporate the stronger energy absorbing bumpers.
TYPES OF BUMPERS
PLASTIC BUMPER
CARBON FIBRE BUMPER
BOBY KIT BUMPER
STEEL BUMPER
PLASTIC BUMPER
Most modern cars use a reinforced thermoplastic bump-
er, as they are cheap to manufacture, easy to fit and ab-
sorb more energy during a crash. A majority of car bump-
ers are custom made for a specific model, so if you are
looking to replace a cracked bumper with a similar one,
you would have to buy from a specialist dealer. However,
many companies now offer alternative designs in ther-
moplastic, with a range of fittings designed for different
models.
BOBY KIT BUMPER
Modified cars often now have a full body kit rather than
just a front and rear bumper. These kits act as a skirt
around the entire body of the car and improve perfor-
mance by reducing the amount of air flowing underneath
the car and so reducing drag. Due to each car's speci-
fications, these have to be specially purchased and can
be made from thermoplastic, like a standard bumper, or
even out of carbon fiber.
CARBON FIBRE BUMPER
Carbon fiber body work is normally the thing of super-
cars, but many car companies, and specialist modifiers,
are starting to use it for replacement body part on every-
day cars. This is because it is very light and is safe during
a crash. It is, however, a lot more expensive than normal
thermoplastic.
STEEL BUMPER
Originally plated steel was used for the entire body of a
car, including the bumper. This material worked well, as
it was very strong in a crash, but it was very heavy and
dented performance. As car engine design has improved,
steel bumpers have pretty much disappeared for anything
except classic cars. Replacing one involves a lot of search-
ing for scrap cars or having one specially made.
INTRODUCTION TO CREO2.0 (PRO/ENGINEER)
Creo2.0 (PRO/ENGINEER)is a feature based, parametric
solid modeling program. As such, it's use is significantly
different from conventional drafting programs. In conven-
tional drafting (either manual or computer assisted), vari-
ous views of a part are created in an attempt to describe
the geometry. Each view incorporates aspects of various
features (surfaces, cuts, radii, holes, protrusions) but the
features are not individually defined. In feature based
modeling, each feature is individually described then in-
tegrated into the part. The other significant aspect of con-
ventional drafting is that the part geometry is defined by
the drawing. If it is desired to change the size, shape, or
location of a feature, the physical lines on the drawing
must be changed (in each affected view) then associated
dimensions are updated. When using parametric mod-
eling, the features are driven by the dimensions (param-
eters). To modify the diameter of a hole, the hole diameter
parameter value is changed. This automatically modifies
the feature wherever it occurs - drawing views, assem-
blies, etc. Another unique attribute of Creo2.0 (PRO/EN-
GINEER)is that it is a solid modeling program. The design
procedure is to create a model, view it, assemble parts as
required, then generate any drawings which are required.
It should be noted that for many uses of Pro/E, complete
drawings are never created. A typical design cycle for a
molded plastic part might consist of the creation of a solid
model, export of an SLA file to a rapid prototyping system
(stereolithography, etc.), use of the SLA part in hands-on
verification of fit, form, and function, and then export of
an IGES file to the molder or toolmaker. A toolmaker will
then use the IGES file to program the NC machines which
will directly create the mold for the parts. In many such
design cycles, the only print created will be an inspection
drawing with critical and envelope dimensions shown.
MODEL OF CAR BUMPER
The above image shows assembly of car bumper with regular
damper pad
The above image shows assembly of car bumper with honey
comb damper pad
The above image shows honey comb structure damper pad

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International Journal of Research and Innovation (IJRI)
IMPACT LOAD CONDITIONS
Speed1=100kmph
For 100kmph&150kmph
FS=1/2mv2
F=1/2(mass)(velocity)2
/s(slowdown)
F=force acting on car bumper
M=mass of the vehicle (1950)
V=velocity in m/s
S=slow down distance=0.5m
1.For 100kmph(27.7)velocity
=100*1000/3600=27.7m/s
F=1/2(2000)(27.7)2/(0.5)=1534.580kn
=1534580n
Pressure=1534580/Area174159484=13.49n/mm2
=MPA
Speed2=150kmph
For150KMPH(41.55)(Velocity)
=150*1000/3600=41.55
=F=1/2(2000)(41.55)2/(0.5)=20.325MPA
MATERIALS AND BOUNDARY CONDITIONS
ALLOY STEEL
E-GLASS EPOXY
S-GLASS EPOXY
RUBBER
NITINOL (memory shape alloy)
STRUCTURAL ANALYSIS OF CAR BUMPER WITH
DAMPER AT SPEED 1
The above image shows imported model
The above image shows meshed model
MATERIAL STEEL AND RUBBER
The above image shows stress
The above image shows displacement
The above image shows strain
MATERIAL E- GLASS AND RUBBER
The above image shows stress
MATERIAL S- GLASS AND RUBBER
The above image shows stress

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International Journal of Research and Innovation (IJRI)
STRUCTURAL ANALYSIS OF CAR BUMPER WITH
DAMPER AT SPEED 2
MATERIAL STEEL AND RUBBER
The above image shows stress
MATERIAL E- GLASS AND RUBBER
The above image shows stress
MATERIAL S- GLASS AND RUBBER
The above image shows stress
STRUCTURAL ANALYSIS OF CAR BUMPER WITH HON-
EY COMB DAMPER AT SPEED 1
MATERIAL STEEL AND RUBBER
The above image shows stress
MATERIAL E- GLASS AND RUBBER
The above image shows stress
MATERIAL S- GLASS AND RUBBER
The above image shows stress
STRUCTURAL ANALYSIS OF CAR BUMPER WITH HON-
EY COMB DAMPER AT SPEED 2
MATERIAL STEEL AND RUBBER
The above image shows stress
MATERIAL E- GLASS AND RUBBER
The above image shows stress
MATERIAL S- GLASS AND RUBBER

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International Journal of Research and Innovation (IJRI)
STRUCTURAL ANALYSIS OF CAR BUMPER WITH HON-
EY COMB DAMPER AT SPEED 1
MATERIAL S- GLASS AND NITINOL
The above image shows stress
The above image shows displacement
STRUCTURAL ANALYSIS OF CAR BUMPER WITH HON-
EY COMB DAMPER AT SPEED 2
MATERIAL S- GLASS AND NITINOL
The above image shows stress
IMPACT ANALYSIS OF CAR BUMPER WITH HONEY
COMB DAMPER AT SPEED 2
MATERIAL S- GLASS AND NITINOL
The above image shows stress
The above image shows strain
GRAPHS
The above image shows displacement graph
The above image shows strain graph
STRUCTURAL ANALYSIS
Car bumper plain dumper pad
steel E glass S glass
Speed1 Speed2 Speed1 Speed2 Speed1 Speed2
Stress 39.58 59.67 40.31 60.77 40.14 60.15
Displace-
ment
1.36 2.06 3.95 5.96 0.329 0.49
Strain 0.0109 0.0165 0.0316 0.047 0.0026 0.0039
Honey comb
Stress 32.97 50.17 33.69 50.78 33.59 50.64
Displace-
ment
1.35 2.07 3.97 5.99 0.3314 0.49
Strain 0.011 0.00013 0.00024 0.00037 2.100082e-5 3.16676e-5
Car bumper (s glass) & dumper (memory shape alloy)
Speed 1 Speed 2
Stress 20.09 40.11
Displacement 0.206 0.395
strain 1.30751e-5 2.5085e-5

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International Journal of Research and Innovation (IJRI)
CONCLUSION
This thesis work is done to determine about “reduction of
impact effect on car bumper using honey comb technol-
ogy”.
Data collection and literature survey is done for the meth-
odology.
As per literature survey 34% safety can be increased.
3D models are prepared for further analysis approach.
Structural analysis is done on general model to evaluate
the result for the comparison purpose.
Structural analysis is done on bumper by changing the
material to CRFP (carbon reinforced fiber polymers).
This material is choose due to its higher yield and com-
pressive strength with in low density/weight.
Analysis was conducted by implementing rubber & mem-
ory shape alloy blocks with honey comb structure instead
of plain pad.
Impact analysis is done on the selected model to deter-
mine FOS of car bumper at high speed collision.
As per the analytical results this project concludes that
car bumper with S-Glass epoxy (CRFP) along with NITIN-
OL honey comb pad work better than previous models
and it increases passenger safety by 70% (while compar-
ing FOS).
Note: S-glass is a low density carbon material with higher
structural stability.
Honey comb technology is widely used in Aerospace
domine due to its higher strength at very low volume of
material (low weight due to honey comb cuttings).
NITINOL is basically a stress based memory shape alloy
which regains its original state/shape at the removing
stress/load.
This material is widely used in dampers.
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author
M.Arun kumar
Research Scholar,
Department Of Mechanical Engineering,
HyderabadInstituteOf Technology And Management,
Hyderabad,India
Y Anil Reddy (project Guide)
Assistant professor
Department Of Mechanical Engineering,
HyderabadInstituteOf Technology And Management,
Hyderabad,India
Godi Subba Rao, (HOD)
Professor,Department Of Mechanical Engineering,
HyderabadInstituteOf Technology And Management,
Hyderabad,India