Session4 Automotive Front End Design

© M S Ramaiah School of Advanced Studies
Session 4
Automotive Front End Design
Session Speaker
Mr. Mithun S. K.

Session Objectives
At the end of this session the delegate would have understood

- Factors affecting front end design
- Front end design for better air cooling
- Bumper design and Regulation for bumper design
- Evolution of grille design
- Current trend in front end design for pedestrian safety
- Hood design and new trends in exterior mirror design

3
Session Topics
1. Front End Module
2. Factors affecting Front End Design
3. Bumper Design and Regulations
4. Mismatch Bumper Heights
5. Front End Design for Better Air Cooling
6. Evolution of Grille Design
7. Grille Design as New Brand Image
8. Current Trend in Front End Design for Pedestrian Impact

4
Front End
• The front-end of the vehicle has seen considerable developments over

the past few years, both in terms of styling and technology
developments in the components.

5
Front Fascia Module
The module consists of

• Fascia
• Bumper beam with crash box
• Radiator intake, duct, and radiator closeout model
6
Front Fascia Module

7
Front End- New Design Trends
The front-end module has different variants :
• Bumper sub-module / Outer module - encompasses the bumper,
fog lamps, grille and air guides
• Inner module - contains the carrier frame, headlights, hood
latch
• Engine-cooling module – contains the radiator, condenser and
the fan and shroud assembly

8
Factors Affecting Design of Front End Module
Package and integration

of components
Flexibility and Crash management-

ease of assembly Factors affecting energy absorption
design of front
end module
Materials used and Exterior design and Fit

position of sensors and finish of module

9
BMW 7 Series(2009)

• Crash management and Component packaging in the vehicle front,

since there needs to be a crumple zone, an energy absorption stiffener
and a cooling module at a lower height to meet the pedestrian safety
standards

11
• Materials used and ease of assembly
• The thermoplastic fender module combines
components such as the windshield cleaning
reservoir, pedestrian protection absorbers, airbag
sensors, headlamps, fog lamps and coolers for
air and oil
• Better crash impact absorption properties of
thermoplastics, useful for pedestrian protection
• Complete fender modules have also recently
been developed as a substitute for front-end
Modules
• Helps to achieve zero shut line gap between the
fender and bumper and the headlamps
12
Front End
• Design Element
• The front end design clearly symbolizing the car’s dynamic
orientation to the road.

13
Design Elements in Front End
• Grille
• Headlamp
• Bumper

14
BUMPER

15
Bumper
• A bumper is a shield made of steel, aluminum, rubber, or plastic that

is mounted on the front and rear of a passenger car.
• When a low speed collision occurs, the bumper system absorbs the
shock to prevent or reduce damage to the car.
16
Bumper
• Some bumpers use energy absorbers or brackets and others are made
with a foam cushioning material.
• Bumper systems have changed drastically over the last 20 to 30 years,
and they continue to change as automakers adjust to new regulations,
strive to improve safety, make vehicles more fuel efficient, and
reduce manufacturing costs
17
Purpose of Bumper
• Shock absorber system • Energy absorbing PUR
form
• The car bumper is designed to prevent or reduce physical damage to

the front and rear ends of passenger motor vehicles in low-speed
collisions.
• It is not a safety feature intended to prevent or severe injury severity
to occupants in the passenger cars.
18
Purpose of Bumper
• Bumpers are designed to protect the hood, trunk, grille, fuel, exhaust
and cooling system as well as safety related equipment such as
parking lights, headlamps and taillights in low speed collisions.
19
Bumper
• The incorporation of crush tubes or crash boxes at the bumper

mounting points, or the provision of the bumpers with a stroking
capability for energy absorption and instant recovery, is a further
important consideration.
20
Bumper side mountings
• Bumper side mountings should be of

the quick release type and not bolted
to the front and rear wing as with
some designs
• The main bumper mountings should
be capable of transmitting impact
forces into the chassis
rail/longitudinal area for maximum
energy absorption and they should not
be an integral part of the bumper
© M S Ramaiah School of Advanced Studies 21

Bumper design theme
• Smooth bumper with a circumferential black stripe as a detail of

the “happy face” that is typical of Volkswagen.
• The rear bumper was designed to match the “happy face” in front

22
Bumper design theme
• Bumper design for face lifting

23
Bumper Design in SUVs
Ramp angle
Overhang angle
• Bumpers are typically higher on light trucks, pick-ups or SUVs than

on passenger cars to provide better clearance for approach and
departure of steep grades or when driving over large rocks and other
objects during off road operations.

24
Additional Tasks of Bumper Structure
• Sensor integration
• Equipment integration headlamp washer system

Grille Design

26
Grille Design
• Perforated area lies in front of radiator and between the front

headlamps
• The modern grille expresses a vehicle's personality by mimicking
features of the face ( esp. the lips, nose, and teeth)
• Grilles suggest a variety of facial mood signs-from the friendly smile
to the emotional
27
Evolution of Grille Design
Model A 1903
Ford Model T
1908-1927 Model A 1928
• Model A (1903 ) had neither a grille nor a vertical front-end.

• From 1908-1927, the Model T had a vertical front end with a framed
radiator as a "proto-grille.”

28
• In the 1940s, grille design shifted

from noses to mouths.
• Mercury's aggressive, tooth-
showing grille of 1946, which
resembled an angry bulldog poised
to bite

29
• Mercury Montclair (1955) featured

a bumper grille housing looked like
free-standing teeth, and thick,
horizontal projections that
resembled tusks. Mercury Montclair (1955)
• From 1955-57, the Ford
Thunderbird featured tusks as well a
mouth-like grille
Ford Thunderbird (1955)

30
• In 1963, the Mercury Breezeway added tusk-like dual headlights to its grille
configuration.

31
• 1967 Mercury Cougar's front end featured a bumper that curled up
on the outer extremities, and an insouciant grille resembling the
silent-bared teeth face of monkeys and apes (Van Hooff 1967).

32
Grille Design – New Brand Image
• The grille is the simplest way to create a brand identity

33
Latest trend-Larger Grille Design
• Horsepower of engines has

gradually increased over the
years, and larger engines require
more air to cool
• Cooling locations shifted
Concept CS

34
Latest trend-Larger Grille Design
• Audi -huge front grilles that

extend from the hood to the
lower edge of the bumper.
• Ford’s new three-bar grille

35
• Latest grille design for Subaru
• The front-end styling features a
wing motif that recalls the origin
of the company as an aircraft
manufacturer
• The grille represents a cross
section of the fuselage in the
center and wings on either side

36
• Radiator grille is used to distinguish model

variants more clearly
• Classic model: a three dimensionally
formed radiator grille reflects solidity and
comfort with a touch of luxury.
C-Class Classic grille
C-Class Avantgarde grille

37
Mercedes-Benz 300 SL Gullwing (1952) C-Class Avantgarde grille (2007)
• Avantgarde model : a visually striking radiator grille with a large,

centrally positioned Mercedes star supported by three horizontally
extended, high-gloss trim sections embellished with chrome: the
typical design features of sporty Mercedes models.

38
Front End Design for Better Engine Cooling
• Front end design is partially depends on

• the air required for engine cooling,
• the relevant temperature in the engine compartment,
• the components installed within the engine compartment.

39
• Cars lost their “faces” because of aerodynamics?

• Due to legal reasons the front bumper usually end up directly in line
with the radiator core
• Leads to two intakes , one above the bumper and another below
• Air outlet at the underneath of the car where static pressure is low

40
• The optimum positioning of the front cooling air inlet on a vehicle

plays an important part in achieving a low cd value along with good
engine cooling characteristics
• Aerodynamic point of view ;front end should be closed?
• Design should compromise the sufficient airflow for engine and
under hood component cooling with less drag
41
Factors Influences the Airflow into the Engine Compartment
• Need for more engine output.

• Improved operating comfort of vehicles.
• Increase in number of auxiliary components like power steering
pump, ABS, large volume air cleaners etc.
• Reduction in free space within the engine compartment
• Auxiliary components themselves are additional heat sources
• Front end design

42
Importance of Aerodynamics in Front End Design
Inclination angle of front end

• Lower stagnation point
• The flow can be improved by chamfering the edge instead of
rounding it.

43
Side Vents
Side vents(gills)
• Gills have become a clew for luxury vehicles

• Aerodynamic importance

44
Side Vents
• Sports cars have long vents

45
Side Vents
• Vents often mark special models

46
Car Design and Pedestrian Impact
• The relative risk of death by

front-corner impact was 26
percent greater among the sharp-
cornered cars.
• In 1971, the design of front ends
of cars that resembled the design
of ancient weapons-spears and
battle axes
Source :SAEC Paper Number 2006-01-0464

47
Car Design and Pedestrian Impact
Front Corner Death Rate Relative risk

Design
Front Other Front Other
Corner Corner
Smooth 0.91 2.13 1.00 0.98
Sharp 1.15 2.19 1.26 1.00
Source : 1990 American Journal of Public Health 0090-0036/90

48
Current Trends in Bumper Design for Pedestrian Impact
• Lower stiffeners:
• Durability and the vehicle
styling??
• The location of the components
results in visual changes in the
front end

49
Bumper mounted sensors and / or bumper airbags
Benefits:
• No change in vehicle styling
• It be applied to any bumper system
with an airbag cover. The energy
absorption of the bumper becomes
irrelevant.
Disadvantages:
• Cost, durability and feasibility of the
system

50
• Alternative energy absorbers.
• Multi-density or ‘tuned’ shape foams and molded plastic energy
absorbers, between the bumper beam and the pedestrian.

51
• Bumper Beam Design:

• There are several proposals to
change the shape of the face of the
beam to eliminate foam ‘bottoming-
out’ and reduce knee bending.
• Flexible beams
• A flexible (usually plastic) beam can
be used to improve pedestrian
impact performance.

52
Add-on structures :
• Add-on structures on the front of
the bumper may be used to
provide energy absorption and
support of the lower limb during
a pedestrian impact.
• Bull Bars are detriment to
pedestrians

53
Front-end design for pedestrian safety
Elastic Front by
Hyundai in QarmaQ
Hyundai Qarma Q
• To reduce the risk of severe injuries in Crossover Utility Vehicles

(CUV) pedestrian collisions
• The outer panel is a thermoplastic material that can recyclable
• Glass-reinforced plastic material also forms hood and fender inner
panels that are designed to provide the crush space and cushioning
needed to prevent serious head injuries.
54
Hood

55
Hood Assembly

56
Head Scoops
• Hood Scoops for high performance race and rally cars , mainly
meant for better engine cooling and aesthetics

57
Head Scoops
• The pop-up hood allows car designers greater freedom in having to

balance the aesthetic of a streamlined hood design with the safety
benefits of adding more protective space over the engine
components.

58
Evolution of Cowl (Scuttle)
• No smooth transition between engine hood and up right dashboard

59
Evolution of Cowl design
• Smooth transition between engine hood and bodywork

60
• 1920 : Cowl as a separate body part, providing mounting area for
styling elements , vehicle lighting and air vents

61
• 1930-1950: Cowl dwindles to a tiny strip between the hood and
bodywork

62
• 1960s –present : Cowl is reduced to a sheet metal or plastic
component ahead of windshield, with perforation for windshield
wiper drive and heating / ventilation/air conditioning inlets
• Concaved space formed by the hood and the windshield

63
• If hood extend back to the windshield and its rear edge is swept
upwards, cowl can be eliminated
• Advantage of cost reduction, larger wiper coverage and reduction of
accident damage

64
Proper Positioning of Scuttle
• Static pressure will be higher than that

of ambient pressure
• Influx will be depend on road speed
http://www.carbodydesign.com

65
• If the leading edge of the hood is too sharp , flow will separate static
pressure at scuttle will be low, leads to low volume flow

66
• Place the inlets (vents) where static pressure is same as ambient

pressure
• Thus air flow through vents will be independent of vehicle speed

67
• Angle between windshield and hood is larger in modern cars (Hood

is too slope, with inclined windshields)
• Leads to decrease in static pressure at scuttle region
• Provide a slot at end of the hood
• Dirt fall into the air intake
• Windshield washer jet , washing jet odor get into cabin

68
Specially shaped
inlet
Slot for wiper
(windshield washer
nozzle located)

69
External Mirrors
• Devices for indirect vision

• Devices to observe the traffic area adjacent to the vehicle which
cannot be observed by direct vision.
• These can be conventional mirrors, camera-monitors or other devices
able to present information about the indirect field of vision to the
driver.

70
External Mirrors
• “Mirror”: a device intended to give a

clear view to the rear, side or front of the
vehicle within the fields of vision

71
External Mirrors
• Field of Vision (according to regulation)
• The field of vision must be such that the driver can see at least a 4 m
wide, flat, horizontal portion of the road, which is bounded by a plane
parallel to the median longitudinal vertical plane and passing through
the outermost point of the vehicle on the driver’s side of the vehicle
and extends from ©20M SmRamaiah
behind the ofdriver’s
School Advancedocular
Studies points to the horizon
72
External Mirrors
• Separation at the mirror housing

73
External Mirrors
• Two possible way to avoid separation

at the mirror housing
• Alter the geometry of mirror housing
• (Restricted by attractive design, low
drag, little wind noise)
• Double lever suspension of rear view
mirror housing

74
Latest Trends in External Mirrors Design

75
Summary/Conclusion
• Factors affecting front end design have been discussed

• Evolution of grille design and current trend in front end design for
pedestrian safety have been introduced

76

Session4 Automotive Front End Design

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© M S Ramaiah School of Advanced Studies

Automotive Front End Design

© M S Ramaiah School of Advanced Studies

At the end of this session the delegate would have understood

© M S Ramaiah School of Advanced Studies

© M S Ramaiah School of Advanced Studies

• The front-end of the vehicle has seen considerable developments over

© M S Ramaiah School of Advanced Studies

The module consists of

© M S Ramaiah School of Advanced Studies

© M S Ramaiah School of Advanced Studies

Package and integration

Flexibility and Crash management-

Materials used and Exterior design and Fit

© M S Ramaiah School of Advanced Studies

© M S Ramaiah School of Advanced Studies

• Crash management and Component packaging in the vehicle front,

© M S Ramaiah School of Advanced Studies

© M S Ramaiah School of Advanced Studies

© M S Ramaiah School of Advanced Studies

© M S Ramaiah School of Advanced Studies

• A bumper is a shield made of steel, aluminum, rubber, or plastic that

• The car bumper is designed to prevent or reduce physical damage to

• The incorporation of crush tubes or crash boxes at the bumper

• Bumper side mountings should be of

© M S Ramaiah School of Advanced Studies 21

• Smooth bumper with a circumferential black stripe as a detail of

© M S Ramaiah School of Advanced Studies

© M S Ramaiah School of Advanced Studies

• Bumpers are typically higher on light trucks, pick-ups or SUVs than

© M S Ramaiah School of Advanced Studies

© M S Ramaiah School of Advanced Studies

© M S Ramaiah School of Advanced Studies

• Perforated area lies in front of radiator and between the front

• Model A (1903 ) had neither a grille nor a vertical front-end.

© M S Ramaiah School of Advanced Studies

• In the 1940s, grille design shifted

© M S Ramaiah School of Advanced Studies

• Mercury Montclair (1955) featured

Ford Thunderbird (1955)

© M S Ramaiah School of Advanced Studies

© M S Ramaiah School of Advanced Studies

© M S Ramaiah School of Advanced Studies

• Horsepower of engines has

© M S Ramaiah School of Advanced Studies

• Audi -huge front grilles that

© M S Ramaiah School of Advanced Studies

© M S Ramaiah School of Advanced Studies

• Radiator grille is used to distinguish model

C-Class Avantgarde grille

Mercedes-Benz 300 SL Gullwing (1952) C-Class Avantgarde grille (2007)

• Avantgarde model : a visually striking radiator grille with a large,

© M S Ramaiah School of Advanced Studies

• Front end design is partially depends on

© M S Ramaiah School of Advanced Studies

• Cars lost their “faces” because of aerodynamics?

© M S Ramaiah School of Advanced Studies

• The optimum positioning of the front cooling air inlet on a vehicle

• Need for more engine output.

© M S Ramaiah School of Advanced Studies

Inclination angle of front end

© M S Ramaiah School of Advanced Studies

• Gills have become a clew for luxury vehicles

© M S Ramaiah School of Advanced Studies