Bumper and crash boxes are vehicle structural elements that convert the collision (kinetic) energy at the collision into deformation energy. Failure of the bumper system to sufficiently absorb the collision energy in the event of a collision will result in the resulting forces being transferred directly to the driver and passenger area. It will result in deaths or injuries to people in the vehicle and further damage to the vehicle. In this study, the collision performance of an existing aluminum crash bumper system produced by the extrusion method with a 40% offset collision analysis is examined. A magnesium crash bumper with improved collision performance is designed by this reference. In this design process, the design of experiment method is used. With the combinations created with the Taguchi method, the long design and analysis process is completed in a shorter time. Taguchi experiment design process; four different design variables and three-level combinations of these variables are used. With the table's help created at the L9 level, models corresponding to the variables are prepared, crash analyzes are performed with finite element analysis, and crash performances are examined. After revealing the results, optimization is carried out with Minitab software; the optimum design is achieved in crash performance and lightness.
During the extrusion of magnesium alloys, temperature change could have a significant effect on the outcome. When this effect is not considered, some commonly known defects might be observed, such as hot cracking. In this study, all samples consist of extruded AZ31 and AM50 magnesium alloys as a solid profile, but the methods by which they are cooled, such as air cooling and water quenching, vary. The effects of cooling methods on tensile-compression behavior and the microstructural properties of the samples were investigated. Test samples were obtained in extrusion direction and perpendicular to the extrusion direction separately for mechanical tests. The main purpose of this study was to investigate the effect of different cooling methods on the mechanical properties and microstructural behavior of AZ31 and AM50 magnesium alloys after extrusion, once different cooling methods were applied. According to the microstructural investigation results, an AM50 magnesium alloy has a finer grain structure as compared with an AZ31 alloy according to both cooling methods in the extrusion process. The average grain size values of both alloys were found to be higher for water cooling. Cooling methods have significant effects on the tensile properties of both alloys, depending on their extrusion directions.
The original version of this chapter was revised: Author provided figure 5 correction and changes in Abstract have been incorporated.The chapter and book have been updated with the changes.
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