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technology, crashworthiness, stiffness Abstract. The design of aluminum alloy front bumper beam is based on steel bumper. The process is divided into two stages. The first stage is topology optimization, and the second stage is size optimization. Two thin-walled, hollow aluminum bumpers with reinforced ribs is obtained after topology optimization. Take the thickness of all surfaces and the distance of two reinforced ribs as design variables to conduct size optimization, while maintain the performances of crashworthiness and stiffness. After optimization two type anti-collision aluminum alloy beams are obtained. The comparison results show that the performances of two type anti-collision aluminum alloy beam are better than steel beam, and the mass is smaller. The performance of second type anti-collision beam is better than the first type, but the mass is bigger.

Lightweight optimization design of automotive aluminum alloy front bumper anti-collision beam