www.ijiarec.com Author for correspondence: 1 Student, Department of Mechanical Engg (CAD/CAM), Holy Mary Institute of Technology and Science, Hyderabad, Telangana, India Volume-5 Issue-4 International Journal of Intellectual Advancements and Research in Engineering Computations Design, analysis, fabrication of composite frontal crash beam for “passenger vehicle” S Shitalkumar Shahaji 1 , Sangamesh Basavaraj Herakal 2 , Vijayanand Pedamuthevi 3 1 Student, Department of Mechanical Engg (CAD/CAM), Holy Mary Institute of Technology and Science, Hyderabad, Telangana, India 2 Associate Professor, Department of Mechanical Engg, Holy Mary Institute of Technology and Science, Telangana, India. 3 Associate Professor, Department of Mechanical Engg,, Holy Mary Institute of Technology and Science, Hyderabad, Telangana, India ABSTRACT In this paper, the analysis is done on the automotive bumper to check the crashworthiness for the passenger safety. The bumper beam analyzed for the steel and composite material with the basic bumper design in the first phase to compare the deformation and energy absorbed during the impact. A design of the automotive bumper must ensure the safety of passenger mean while, it needs to have low weight. With the role of safety, fuel efficiency and emission gas regulations are being more important in recent years that enforce the manufacturer to reduce the weight of passenger cars. In this research, a front bumper beam made of steel and composite materials to provide more energy absorption in the structural at the front of the bumper and is studied for impact modelling to determine the deformation and energy-absorption behavior. INRODUCTION Information about bumper beam Bumper beams are one of the important structures in passenger cars. For which we need to have careful design and manufacturing in order to ensure good impact behavior. The new bumper design must be flexible enough to reduce the passenger and occupant injury and stay intact in low-speed impact besides being stiff enough to dissipate the kinetic energy in high speed impact. The bumper beam is the key structure for absorbing the energy of collisions. Since, this is energy absorbing structure suitable impact strength is the main requirement for such a structure, this research analyses the parameters that directly affects impact characteristics and proposes easily achievable modifications resulting from impact modeling on commercial bumpers. A passenger car bumper is modeled and tested for the impact. With the introduction of automobile safety legislation, crashworthiness and safety should be considered as preconditions in light-weight design of bumper beam. There were four main strategic parameters being studied in the test modeling in the first step for metallic material. Firstly, the material i.e., how the type of material can affect the impact specifications and what kind of materials can be used as replacement in order to lower part weights. Steel and aluminum structures with a specified thickness that did not fail during the test depicted clearly that they are not suitable as bumper beam structure due to increasing weight. They increased the weight of the structure by nearly 500% and 100% respectively, in comparison with the composite bumper. ISSN:2348-2079