Today in the development of cars and especially chassis parts, it is necessary to involve all aspects of part properties and the manufacturing process. For solving these additional requirements, involving simulation methods for the manufacturing process and advanced optimization methods are the keys for better chassis parts. For the optimization of the position of sheets and their general shape, morphing and parametric CAD can be used. Morphing is relatively easy to implement and the needed time to investigate single structure elements is acceptable. So morphing offers the possibility to reduce the development time and to find better solution for single elements. The parametric CAD gives a much more degree of freedom but this method is coupled with more time for preparing and optimization. For the usage in parametric CAD into the standard development process, faster concepts for preparing and more efficient algorithms must be developed. The bead optimization is specialized inside the shape optimization. Only the surface of a sheet can be modified. But with this instrument, it is possible to increase the stiffness of a structure and in combination with Evolutionary Algorithms, stress values in weldings can be reduced in a very effective way. So, for the optimization of sheet structure no methods rule over the other approaches. Several ways exists with advantages and disadvantages. The designer is still needed for the general design may be supported with parametric CAD, if enough time exits. But in detail, morphing and bead optimizations can be very effective. Benefits of these new methods are in middle 10 to 20 % better technical properties, the design has a higher quality and through this, 30 % development time can be saved. After the first design phase, the development loop between designer and simulation engineer is supported through an automatic simulation process and automatic documentation establishes a fast development speed. At the end of one development cycle, it is necessary to increase the prediction quality of the simulation results compared with the testing results. With the integration of the forming simulation, it is possible to forecast the later testing results with a difference of 1 kN. This difference is inside the spreading of test results.
Improving the development of sheet structures with optimization and simulation methods
2014
11 Seiten, Bilder, 9 Quellen
Aufsatz (Konferenz)
Englisch
Improving the development of sheet structures with optimization and simulation methods
Springer Verlag | 2014
|Improving the development of sheet structures with optimization and simulation methods
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