Objectives The purpose of this paper is to study optimization methods and apply them to automobile plastic parts development. With the floor console development as an example, some optimization methods have been applied to the design with different stage. As the console design with optimization developed successfully, a new guideline came out to the plastic console development. It’s with great meaning to the other plastic subsystem development on the vehicle. Methodology As optimization has been used very well on metal parts of vehicle, we apply these methods to the plastic parts for the first time, and design the floor console successfully. In this process, topology optimization, shape optimization and size optimization have been used properly with the design came to different stage. At first, topology optimization was used to find the load path and body_join position; then, shape optimization or topology optimization was applied to find detailed structure design; and then, lightweight was done with gauge optimization. Every optimization has been run many times to find the best structure for the mathdata, until the design met the targets in the standard. Result With structure optimization applied on floor console development, the mass of floor console was reduced about 12 %. And a procedure which could guide floor console development successfully was come out. This procedure is not only used in console development, but also can apply to other plastic parts on vehicle, such as IP trim, door trim and pillar trim. Limitation In this chapter, the floor console has reduced 1.3 kg in optimization, but only 1.0 kg mass has come true on the hard tooling model. This is because in optimization, not every parameter of injection molding can be set in software, and the ideal thickness CAE analyzed won’t be realized in the injection molding. At the same time, many other parameters of the floor console design should be considered. So the mass reduction in hard tooling parts is not equal to that in optimization software. Innovation and Conclusions All the analysis shows that the optimization is effective and feasible on plastic system design. It is the first time to apply optimizations all through the console development successfully. The optimization flow can be a console design guideline. Also this process can not only guide the console development, but also other plastic subsystems. It’s with great meaning to the development of automobile development and lightweight.
A Study and Application of Optimization on Console Development
Lect. Notes Electrical Eng.
2012-11-15
11 pages
Article/Chapter (Book)
Electronic Resource
English
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