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Load Distribution by Rear Bumper Beam in FMVSS 301R Test Protocol

Article of Honda R&D Technical Review Vol.32 No.1

Summary

In the present research, technology was established for compliance with Federal Motor Vehicle Safety Standard (FMVSS) 301R, which is a US regulation addressing rear-end collisions. The FMVSS 301R test procedure is an offset impact test using a deformable impact barrier. In offset impact tests, there is a large difference in load input between left and right frames, and there is less deformation in the non-collision-side frame, meaning the side that does not impact with the barrier. Attention was therefore focused on the rear bumper beam, and steps were taken to increase the energy absorption of the non-collision-side frame by having the load from the barrier transferred equally to both frames. The rear bumper beam was structured so that the load input from impact with the barrier would become symmetrical. The stretch bending manufacturing method was used for practical implementation of this concept, and the beam was shaped so that it could be located within the design space of mass-production vehicle. Verification was conducted using a prototype that supposed mass production, demonstrating that the difference in input between the left and right frames, which formerly was large, could be reduced and a more nearly symmetrical load distribution achieved.

Reference

(1) NHTSA: Fuel System Integrity – Rear Impact, Laboratory test procedure for FMVSS 301R, U.S. Department of Transportation National Highway Traffic Safety Administration, (2009)
(2) Okada, E.: Hottosutanpu to kōrudosutanpu, insatsu zasshi, Vol. 90, No. 7, p. 25-28, (2007) (in Japanese)
(3) Fukuchi, H., Nomura, N.: Automotive Solution: Development of Hot Stamping with High Productivity, Shinnittetsu Sumikin giho, Vol. 402, p. 70-72, (2015) (in Japanese)
(4) Maki, H., Takaki, N.: Application of Next-generation High-lambda-type High-strength Steel Sheets, Transactions of Society of Automotive Engineers of Japan, Vol. 48, No. 6, p. 1347-1352, (2017)(in Japanese)
(5) Ishitobi, H., Fujiwara, A.: Deformation of Aluminum Bumper Beam in Corner Pendulum Impact Test, Transactions of Society of Automotive Engineers of Japan, Vol. 29, No. 2, pp. 97-102, (1998)(in Japanese)
(6) Yabu, T., Yasuhara, S.: Development of Rear Bumper Beam Using Thermoplastic Glass Fiber-reinforced Plastic, Honda R&D Technical Review, Vol. 30, No. 1, p. 60-65
(7) Mori. T., Hamano. H., Suzuki.T,. Yoshitake, A,. Hashimoto. Y., Iwase, I.: Application of Ultra-high Strength Steel Sheets to Bumper Beams, NKK Technical Report , Vol. 151, p. 17-21, (1995) (in Japanese)
(8) Yasuhara, S., Egawa, Y.: A Study of Rear Frame Construction for Rear Offset Collision Mode, Transactions of Society of Automotive Engineers of Japan, Vol. 39, No. 6, p. 71-75, (2008)(in Japanese)
(9) Paulsen, F., Welo, T.: A design method for prediction of dimensions of rectangular hollow sections formed in stretch bending, Journal of Materials Processing Technology, Vol. 128, Issues 1-3, p. 48-66, (2002)

Author (organization or company)

Atsushi HASEGAWA(Automobile Center)、Takayuki FUJII(Automobile Center)、Norikazu MATSUURA(Automobile Center)、Tomohiro SHIMIZU(BENTELER Automotive K.K.)、Yusuke MIURA(SOLIZE Engineering Corporation)

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