Lightweight of Aluminum Alloy Bumper Based on High-Speed Crash Component Test

High-speed crashworthiness characteristics of aluminum alloy bumper were investigated both experimentally and numerically, and then lightweight deign was performed based on these studies. After the simulation results were analyzed, chose plate thickness matching as an optimization direction and got crashworthiness indicators: cross-sectional force, energy absorption, and specific energy absorption (SEA). Design of experiment (DOE) for initial 25 sampling points, which provide input data for approximation, is implemented using the optimal Latin hypercube design (OLHD) method. Polynomial response surface (PRS) models, which are used to approximate LS-DYNA simulation models, are built using the moving least square (MVS), whose all coefficients of determination are over 0.97, indicated high accuracy. The simulation results of optimal designs, which are obtained after 52 iterations of genetic algorithms (GA), show that the mass loss of 30.8%, while energy absorption increase of 4% , SEA increase of 50.3%, and crushing forces decline.