This paper has highlighted some of the key findings of a study into the potential for applying structural optimisation algorithms within the field of crashworthiness, given the objective of minimising mass. The paper commenced with a study on HEV BIW architecture design using topology optimisation, followed by shape- and size optimisation for developing the detailed geometry of the front crash structure. It was found that topology optimisation on its own was adequate for safety cage development, but not for the automatic generation of the front end crash structure. The linear static topology optimisation can be used for BIW development, however the engineering interpretation of the results are essential. To "automatically" develop crash structures from design envelopes, thus minimising the "manual design work", a topology optimisation algorithm using non-linear FEA (currently not available in commercial software) could provide an improved "starting point" for the shape- and size optimisation. If this was to be achieved, the "originally engineered" structure in Fig. 5 could theoretically be replaced with the direct outcome of topology optimisation. Research into the development of such an algorithm is presently ongoing. The second part of the study demonstrated that shape- and size optimisation of crash structure components can indeed be successfully completed. However, this process is very complex, due to various factors such as initial design, design space, sampling method, metamodelling technique, optimisation algorithm, mesh and morphing strategy, which all need to be respected. The initial design was found to be a significant factor which ultimately determined the success of the shape- and size optimisation. As mentioned above, a non-linear topology optimisation algorithm could "automatically" deliver an improved proposal for crumple zones, thus enhancing the combined efficiency of the entire optimisation process, which potentially could significantly decrease the time used for the overall design process. The shape- and size optimisation study concluded that the most appropriate methodology for creating an accurate and smooth metamodel for robust optimisation with respect to crashwothiness and mass reduction, was the MLS method combined with HS. This method can be used to efficiently and accurately optimise the cross sectional properties (i.e. shape and size) of a BIW crash structure, whilst meeting NCAP requirements. This was substantiated by dynamic (explicit) FE modeling verifying the outcomes of the shape- and size topology optimisation.
Lightweight body in white design using topology-, shape- and size optimisation
EVS, Electric Vehicle Symposium, 26 ; 1578-1589
2012
12 Seiten, 17 Bilder, 16 Quellen
Conference paper
English
New body in white concept through topology optimisation
British Library Conference Proceedings | 2004
|New body in white concept through topology optimisation
Tema Archive | 2004
|Effects of roof crush loading scenario upon body in white using topology optimisation
Tema Archive | 2012
|Effects of roof crush loading scenario upon body in white using topology optimisation
Taylor & Francis Verlag | 2012
|Lightweight design of automotive front rail based on topology optimisation and collision analysis
Taylor & Francis Verlag | 2024
|