Abstract: The strength and energy absorption parameters of the anticollision beam of a steel bumper are obtained by three-point static pressure test and simulation. After that material substitution is carried out and a new aluminum alloy beam is designed by structure optimization method based on the performance of the steel beam. The “日” glyph optimal cross-section is determined through optistruct topology optimization. Taking the thickness of each plate and the cross-section changed by Hypermorph as design variables, size and shape optimization is completed through Hyperstudy and LS-DYNA united simulation. The results converge after 13 iterations. According to the optimization results some samples are manufactured. Finally, three-point static pressure experiment and comparative analysis are completed to verify that the new anticollision beam will be just 38.4% lighter than the steel part, and the peak of the static pressure reaction force is enhanced by 11.1%. Its specific energy absorption(SEA) is 1.9 times larger than that of the steel part. In conclusion, the performance of the new aluminum alloy beam is excellent.

Key words: Aluminum alloy, Anticollision beam, Three-point static pressure test, Topological optimization, United simulation