The optimization process with the target of minimum weight design of a foam-filled three-dimensional thin-walled S frame under the prescribed values of stiffness and energy absorption was formulated and solved. A distinctive feature of the present approach is that the response function is given as an analytical expression. Three design parameters were introduced in this study, which are the width of the column wall, gauge thickness, and the relative foam density. The sequential quadratic programming (SQP) was employed to find the optimum design variables and the necessary calculation can be completed within a few minutes. Comparing with the optimized empty S frames, about 75% increase in the specific energy absorption was achieved for the aluminum foam-filled S frames. All the analytical solution and the optimization results were verified with the confirmation runs made by commercial FE code PAM-CRASH. The error was within 6%. It was observed that least weight is achieved with a low relative foam density (of an order of 5%) and a thin gauge outer shell. Also, the cross-sectional dimensions b x b are realistic from the packaging point of view (for example, 90 mm x 90 mm). The present methodology can be used as a valuable tool in the early stage of crash-oriented car body design.
Weight and crash optimization of foam-filled three-dimensional "S" frame
Gewichtsminimierung und Optimierung der Energieabsorption eines Aufprallpuffers, bestehend aus einem schaumstoffgefüllten Blechrahmen mit dreidimensionaler S-förmiger Struktur
Computational Mechanics ; 28 , 5 ; 417-424
2002
8 Seiten, 10 Bilder, 2 Tabellen, 14 Quellen
Article (Journal)
English
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