Design and optimization of a new composite bumper beam in high-speed frontal crashes

Normally, automobile bumper system absorbs the collision kinetic energy by deflection in low-speed crash and by deformation in high-speed crash. The main component of this system is the bumper beam, generally made of steel. The purpose of this paper is to improve energy absorption and light the weight of bumper by applying Fruit Fly Optimization Algorithm (FOA) in frontal bumper beam. The simulation of the frontal crash by using the Finite Element (FE) model is based on the New Car Assessment Program (NCAP). The most important parameters including the type of materials, thicknesses and layup of composite layers are studied by Rescaled Range Analysis (RRA). Then, the diminution of the value of Head Injury Criterion (HIC) is treated as optimization objective in the simulation of FE model, the thicknesses of composite beam are designed and analyzed through Fruit Fly Optimization Algorithm (FOA). In addition, the optimization results are compared with the results analyzed by Genetic Algorithm (GA). It can be observed from the results that the value of HIC is reduced by 6.37 %, the new composite beam will be just 4.84 % lighter than the steel part, and its peak value of collision energy absorption is 1.36 times larger than that of the steel part. In conclusion, the FOA can be applied in design of the new composite bumper beam in improving energy absorption and lightweight.