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Billions of dollars are spent each year to repair damage to vehicles after collisions, many of which are low speed impacts. In an attempt to replicate real world bumper to bumper damage patterns, the Insurance Institute for Highway Safety(IIHS) has conducted new series of low speed bumper tests, and most bumpers of test vehicles are failed to protect expensive vehicle components from safety equipments to various exterior parts. This paper treats a process to study a frontal bumper structure to meet the new IIHS low speed bumper test revised on June 2006. In particular, this study focuses on improving the crash performance by means of diminishing repair costs, and approaches with two test subjects; a full overlap and a 15% offset frontal test. Throughout finding design parameters of a bumper beam, the optimized beam reinforcement and the required overlap percentage of a beam are found using the Design of Experiments (DoE) with help of CAE models. In addition, the paper shows a verification of the crash performance by correlating simulations and physical crash tests of carts and real cars. and eventually compares collision repair costs between manufactured and newly developed bumper systems.

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UCI(KEPA) : I410-ECN-0101-2009-556-015699381