This article deals with the design and weight optimization of a multi-functional vehicle body panel in an automotive context. An existing vehicle design has provided functional design requirements regarding static, dynamic, and acoustic behavior of the components of a car roof. A novel, multifunctional panel is proposed which integrates the component requirements present in a traditional roof system within a single module. The acoustic properties of two configurations of the novel panel are examined using numerical methods including advanced poro-elastic modeling tools compatible with Nastran, and compared with numerical results of a finite element model of the existing construction. Two different configurations of sandwich panel have been proposed, and weight optimized against a set of structural requirements obtained from engineering documentation and analysis of an existing verified FE model. Each panel consists of four layers; two face sheets, one layer of acoustic foam, and one layer of structural foam. For one of the panels, the inner face sheet is perforated. The effect of the perforations on the weight optimization has very little effect on the outcome of the structural optimization, both panels varying only slightly in mass and thickness. After optimization, the panels were evaluated using nonlinear buckling analysis to assess potential to support transverse loading. Finally, the acoustic properties of the panels are assessed over a range of frequencies and compared with the current state of the art. The concept of a multifunctional body panel having structural and acoustic functionality has been explored, and results show promise. A reduction in mass of more than 80 % compared to the conventional configuration was achieved for both sandwich configurations while still fulfilling static and dynamic stiffness constraints. Both sandwich panels are capable of sustaining a uniform transverse in-plane load equivalent to the maximum buckling load of the rear transverse beam of the conventional construction. Coupled fluid structure analysis shows that both sandwich configurations behave similarly to the conventional configuration and despite the vast reduction in mass, no acoustic degradation occurs and in fact a small improvement may have been achieved. Results of the optimization yield a broad design space for future structural and acoustic improvements regarding the materials and configuration of the structural components and the acoustic treatment.
Structural-acoustic design of a multi-functional sandwich panel in an automotive context
Journal of Sandwich Structures and Materials ; 12 , 6 ; 684-708
2010
25 Seiten, 12 Bilder, 3 Tabellen, 36 Quellen
Aufsatz (Zeitschrift)
Englisch
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