USING CAE TO EVALUATE STRUCTURAL FOAM ALTERNATIVES IN B-PILLAR AND BUMPER DESIGNS

This study examined the viability of using structural foam designs as lightweight alternative in B-pillar and bumper designs. The B-pillar was evaluated for side impact performance with respect to intrusion, while the rear bumper was evaluated for low speed impact performance with respect to intrusion and energy absorption. Typical stamped steel structures were used as baselines. Structural foam designs were evaluated using simulation and iterated until similar performance was achieved. Simulation results showed that the final design iteration of both the B-pillar and rear bumper achieved performance equivalent to the baseline with the benefit of reduced weight.