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The biggest challenge in vehicle BIW design today is to make a light, cost effective and energy absorbing structure. With the increasing competition as well as increasing customer awareness, today’s vehicle has to satisfy several aesthetic and functional requirements besides the mandatory regulatory requirements. Working on global platform is challenging in order to comply with both pedestrian protection and low speed bumper impact (ECE-R42) and, at the same time, to meet the styling intent of reducing the front overhang. Pedestrian lower leg compliance demands space between bumper member and bumper: a condition that reduces the space available for energy absorption during low speed impact (ECE-R42). Therefore, reduction in front overhang poses a problem in meeting both the requirements with limited space. This paper outlines vehicle case study in order to optimize the design of Bumper Beam structure, for complying with regulatory requirements while satisfying the styling intent.

Vehicle Hood being the face of a passenger car poses the challenge to meet the regulatory and aesthetic requirements. Urge to make a saleable product makes aesthetics a primary condition. This eventually makes the role of structure optimization much more important. Pedestrian protection- a recent development in the Indian automotive industry, known for dynamics of cost competitive cars, has posed the challenge to make passenger cars meeting the regulation at minimal cost. The paper demonstrates structure optimization of hood and design of peripheral parts for meeting pedestrian protection performance keeping the focus on low cost of ownership. The paper discusses development of an in-house methodology for meeting Headform compliance of a flagship model of Maruti Suzuki India Ltd., providing detailed analysis of the procedure followed from introduction stage of regulatory requirement in the project to final validation of the engineering intent.

Automotive industry today faces the unprecedented challenges both in terms of adapting to changing customer demands in terms of vehicle aesthetics, features or performance as well as meeting the mandatory regulatory requirements, which are being regularly upgraded and becoming stringent day by day. Vehicle hood, being part of vehicle front fascia, needs to fulfill the requirement of vehicle aesthetics as its primary condition. At the same time, every automobile manufacturer has a lineup of older platforms, which are in production and needs to comply with upcoming stricter safety norms, having a structure in under hood area designed as per older philosophy, which further reduces the space available for energy absorption. This makes the structure optimization in vehicle hood area much more challenging. Pedestrian protection - an upcoming regulation in India, has seen some major development in recent times.

The biggest challenge in vehicle BIW design today is to make a light, cost effective and energy absorbing structure. With the increasing competition as well as increasing customer awareness, today’s vehicle has to satisfy several aesthetic and functional requirements besides the mandatory regulatory requirements. While working on global platform, it is challenging to comply with both pedestrian protection and low speed bumper impact (ECE-R42) and at the same time meeting the styling intent of reducing the front overhang. Pedestrian lower leg compliance demands space between bumper member and bumper, a condition that reduces the space available for energy absorption during low speed impact (ECE-R42). Therefore, reduction in front overhang poses a problem in meeting both the requirements with limited space. This paper outlines vehicle case study in order to optimize the design of Bumper Beam structure, for complying with regulatory requirements while satisfying the styling intent.