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Development of Rear Bumper Beam Using Thermoplastic Glass Fiber-reinforced Plastic

Article of Honda R&D Technical Review Vol.30 No.1

Summary

Parts design technology that uses thermoplastic glass fiber-reinforced plastic with high-impact strength was developed to reduce the rear bumper beam weight. Both continuous fiber that provides good impact resistance and chopped fiber that is advantageous for molding complex shapes were applied to create the ideal impact-resistant design for the rear bumper beam. Short process molding technology was also developed that can simultaneously mold three types of materials with different fiber formats in the same mold in order to reduce parts weight and cost. In addition, the influence of the rib shape on product performance in this molding process was clarified, and design technology that reduces that influence was concurrently developed.
The developed technology was applied to the rear bumper beam that is part of the frame of a mass-production vehicle, and enabled a reduction of the weight by 46% and the number of parts, except for fastening parts, to 1/9 that of the previous model.

Reference

(1) Omiya, Y., Sano, T., Minoura, T.: Latest Trends in Automobile Body Materials, KOBE STEEL ENGINEERING REPORTS, Vol. 57, No. 2, p. 2-7, (2007) (in Japanese)
(2) Ishikawa, T.: Overview of Carbon Fiber Reinforced Composites (CFRP) Applications to Automotive Structural Parts - Focussed on Thermoplastic CFRP -, Journal of the Japan Society for Precision Engineering, Vol. 81, No. 6, p. 489-493, (2015) (in Japanese)
(3) Thomason, J. L.: The influence of fibre length and concentration on the properties of glass fibre reinforced polypropylene: 5. Injection moulded long and short fibre PP, Composites Part A: Applied Science and Manufacturing, Vol. 33, p. 1641-1652, (2002)
(4) Yasuhara, S., Yabu, T.: Structure Proposal of Reducing the Temperature Dependence in Car Body Application of Thermoplastic Composite Materials, Transactions of Society of Automotive Engineers of Japan, Vol. 46, No. 1, p. 207-212, (2015) (in Japanese)
(5) Yabu, T., Yasuhara, S., Kashiwagi, M.: Development of Bumper Beam Structure by GFRTP Sheet, JSAE Annual Congress Proceedings, No. 50-16, p. 1216-1220, (2016) (in Japanese)
(6) Yabu, T., Yasuhara, S., Kashiwagi, M.: Research of Design Method of Crash Box Made by Thermoplastic GFRP, Transactions of Society of Automotive Engineers of Japan, Vol. 48, No. 4, p. 945-952, (2017) (in Japanese)

Author (organization or company)

Tomoya YABU(Automobile R&D Center)、Shigeto YASUHARA(Automobile R&D Center)

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