In order to remain competitive in the marketplace, all motor vehicle manufacturers face difficult decisions with regard to balancing cost vs. feature. That is to say that the manufacturer must balance the cost of the product to the customer to remain competitive whilst offering appropriate technology and standard features required by that customer. All motor manufacturers are therefore under pressure to keep costs of nonfeature items to a minimum. One of the cost reductions items prevalent on most vehicles is the deletion of the structural member that attaches the rear bumper, known as the bumper beam (RBB), which is researched in this Thesis. This generates average vehicle savings of $20 and, as this is invisible to the customer, should enable the manufacturers to realise a significant saving or allow this revenue to be spent on additional feature without loss of vehicle function. However, in nearly all cases, deletion of the rear bumper beam has the effect of degrading the steering responses of the vehicle by 1 to 1½ rating points (out of 10), which is contrary to the premise of cost reductions; which is to ensure that vehicle function is unaffected. Initial analysis of vehicles with deleted rear bumper beams cannot show an objective measurable difference in any vehicle behaviours with or without the beam fitted, and hence CAE studies using ADAMS models cannot verify the effects of the bumper beam. It was necessary to employ unconventional modelling and testing methods such as rigid body, flexible body model techniques as well as experimental studies included driving robots and expert driver appraisals. The research demonstrated that vehicle modelling methods currently used, cannot establish or predict the complete vehicle ride and handling status. A total vehicle model approach should be used without separating the body CAE model and vehicle dynamics ADAMS model into separate entities. Furthermore, it was concluded that the determination to the effects of body hysteresis rather than pure stiffness is of crucial importance and that the steering attribute could be maintained with the deletion of the RBB analytically.

In order to remain competitive in the marketplace, all motor vehicle manufacturers face difficult decisions with regard to balancing cost vs. feature. That is to say that the manufacturer must balance the cost of the product to the customer to remain competitive whilst offering appropriate technology and standard features required by that customer. All motor manufacturers are therefore under pressure to keep costs of nonfeature items to a minimum. One of the cost reductions items prevalent on most vehicles is the deletion of the structural member that attaches the rear bumper, known as the bumper beam (RBB), which is researched in this Thesis. This generates average vehicle savings of $20 and, as this is invisible to the customer, should enable the manufacturers to realise a significant saving or allow this revenue to be spent on additional feature without loss of vehicle function. However, in nearly all cases, deletion of the rear bumper beam has the effect of degrading the steering responses of the vehicle by 1 to 1½ rating points (out of 10), which is contrary to the premise of cost reductions; which is to ensure that vehicle function is unaffected. Initial analysis of vehicles with deleted rear bumper beams cannot show an objective measurable difference in any vehicle behaviours with or without the beam fitted, and hence CAE studies using ADAMS models cannot verify the effects of the bumper beam. It was necessary to employ unconventional modelling and testing methods such as rigid body, flexible body model techniques as well as experimental studies included driving robots and expert driver appraisals. The research demonstrated that vehicle modelling methods currently used, cannot establish or predict the complete vehicle ride and handling status. A total vehicle model approach should be used without separating the body CAE model and vehicle dynamics ADAMS model into separate entities. Furthermore, it was concluded that the determination to the effects of body hysteresis rather than pure stiffness is of crucial importance and that the steering attribute could be maintained with the deletion of the RBB analytically.

O presente trabalho visa o estudo e avaliação de diversos modelos de falha através de ensaios experimentais e análises numéricas. A caracterização do material foi feita por meio de ensaios de tração de espécimes com e sem entalhe e de cisalhamento, para prover dados em uma ampla faixa de triaxialidade. A calibração dos parâmetros necessários para cada modelo de falha ocorreu através da obtenção das componentes de tensões e de deformações na região de ruptura, obtidas por meio de análises numéricas destes ensaios. O critério da máxima deformação plástica equivalente, modelo de dano de Johnson-Cook e critério da máxima tensão cisalhante foram aplicados em um caso de impacto em pára-choque. Diversos ensaios de impacto foram realizados até a que se atingisse a ruptura satisfatória do componente. Os ensaios foram modelados em elementos finitos, através do programa comercial LS-Dyna®, sendo que os modelos de falha calibrados foram aplicados para o ensaio onde se ocorreu ruptura. Houve boa concordância entre os resultados obtidos numericamente e experimentalmente, respeitadas as observações realizadas acerca da especificidade deste caso de impacto em baixa velocidade. / The aim of the present work is an assessment of several fracture models through experiments and numerical simulations. Tensile tests with notched and unnotched specimens were carried out to provide the material characterization in a wide range of stress triaxiality. The calibration of the parameters required by the fracture models was enabled by the parallel numerical simulation of the tensile tests, providing information on the stress and strain components at the failure locus. The constant equivalent strain criterion, the Johnson-Cook failure model and the maximum shear stress failure criterion were applied in a bumper beam impact case study. Several low speed impact tests were carried out in order to result in the components rupture. Numerical simulation of the experiments was performed using commercial finite element code LS-Dyna®. Good correlation of experiments and numerical simulations was achieved when considering this particular low speed case study.

O presente trabalho visa o estudo e avaliação de diversos modelos de falha através de ensaios experimentais e análises numéricas. A caracterização do material foi feita por meio de ensaios de tração de espécimes com e sem entalhe e de cisalhamento, para prover dados em uma ampla faixa de triaxialidade. A calibração dos parâmetros necessários para cada modelo de falha ocorreu através da obtenção das componentes de tensões e de deformações na região de ruptura, obtidas por meio de análises numéricas destes ensaios. O critério da máxima deformação plástica equivalente, modelo de dano de Johnson-Cook e critério da máxima tensão cisalhante foram aplicados em um caso de impacto em pára-choque. Diversos ensaios de impacto foram realizados até a que se atingisse a ruptura satisfatória do componente. Os ensaios foram modelados em elementos finitos, através do programa comercial LS-Dyna®, sendo que os modelos de falha calibrados foram aplicados para o ensaio onde se ocorreu ruptura. Houve boa concordância entre os resultados obtidos numericamente e experimentalmente, respeitadas as observações realizadas acerca da especificidade deste caso de impacto em baixa velocidade. / The aim of the present work is an assessment of several fracture models through experiments and numerical simulations. Tensile tests with notched and unnotched specimens were carried out to provide the material characterization in a wide range of stress triaxiality. The calibration of the parameters required by the fracture models was enabled by the parallel numerical simulation of the tensile tests, providing information on the stress and strain components at the failure locus. The constant equivalent strain criterion, the Johnson-Cook failure model and the maximum shear stress failure criterion were applied in a bumper beam impact case study. Several low speed impact tests were carried out in order to result in the components rupture. Numerical simulation of the experiments was performed using commercial finite element code LS-Dyna®. Good correlation of experiments and numerical simulations was achieved when considering this particular low speed case study.