Improving of high performance passive vehicle safety systems taking into account of sheet forming effect

One of the most common vehicle crushes is front collision crushes. To prevent these crushes, several safety systems are developed which is energy absorber and bumper system that are components to prevent drivers and passengers to get harmed with absorbing the energy consisted in crushes. Nowadays, there are many researches on bumper and impact absorber geometries. The objective of them is to make optimum design for components to absorb the consisted energy for driver and passengers to get most less harm. However, they that produced with sheet forming methods, suffer from plastic strain which causes nonuniform distribution. Therefore, excluding the forming effect in collision analyses causes incorrect results for the collision analyses. Within the scope of the project, preform designs and collision analyses is carried out to get optimum design of bumper and impact absorbers, Their model's parameter specifications carried out to be able to do optimisation running and models are created by using Taguchi tables. Results are obtained by the models that subjected to crash analyses. Optimum impact absorber and bumper model is created with the respons surface approachment equations that using differential evolutionary algorithm. The design model is both subjected to collision analyses with ideal conditions (without the effect of sheet forming) and sheet forming analyses are done on Hyperform program and solved by adding the forming past to collision analyses. A new energy absorber and bumper model is revealed that performs better on collision and yields on weight than the base model by the numerical analyses results.