Case Study of SUV Hatchback: ‘Material-Structure-Process-Performance’ Integration Design and Numerical Verification of Automotive Composite Components

2017 ◽  
Author(s):  
Cheng Zhang ◽  
Ning Kang ◽  
Lijun Li ◽  
Lingyu Sun
Keyword(s):  
Design Method ◽  
Lightweight Design ◽  
Integrated Design ◽  
Resin Matrix ◽  
Material Structure ◽  
Numerical Verification ◽  
Rtm Process ◽  
Design Variables ◽  
Filling Time ◽  
Torsion Stiffness

Substitution of steel by lightweight resin-matrix composites is an effective way of weight reduction for automobiles. In this paper, an integrated design method involving material property, structural geometry, process formability and resultant performance for automotive composite components is proposed. Referring to the exterior styling and assembly space of original steel reference, the conceptual CAD model is established. For the selected materials, optimization of minimizing the mass is carried out with layer thickness, stacking sequence and dimensions of each composite component as design variables, referring to the regulations requirements on performance of steel benchmark as constraint conditions. Then the resin transfer molding (RTM) process is simulated and optimized to determine the optimal forming parameters. As an example, a SUV hatchback with composite laminate is developed by RTM technique. Finally, the lightweight design of hatchback is achieved under the multiple constraints of static bending, torsion stiffness and vibration frequencies. The results show that the weight of SUV hatchback has been reduced 38.8%, whereas the stiffness and frequency all meet the requirements. When manufacturing with RTM process, the filling time of the final optimized program is 443 s, without any air trap. This instance has validated the effectiveness and feasibility of the integrated design method which is also applicable to other automotive composite components.

Integrated Optimal Design of Ducted Propeller Based on DOE

2011 ◽  
Vol 291-294 ◽  
pp. 1698-1703 ◽  
Author(s):  
Zhuo Yi Yang ◽  
Yan Ma ◽  
Yan Xue Chen
Keyword(s):  
Design Method ◽  
Integrated Design ◽  
Panel Method ◽  
Hydrodynamic Performance ◽  
Surface Panel Method ◽  
Optimal Method ◽  
Scheme Design ◽  
Propeller Design ◽  
Design Variables ◽  
Ducted Propeller

Ducted propeller is a normal thrust used widely in ship field, and the traditional design method could be improved by advanced computer technology of integrated design. Surface panel method predicting hydrodynamic performance of propeller and CFD were both used here, to ensure the results from surface panel method were believable. Surface panel program of ducted propeller was integrated in iSIGHT optimization platform, where the pitches in different radius were optimized and studied to find the best scheme. Design of experiment was selected as optimal method. Design variables were auto-chosen in the design space and optimal process was auto-executed. Besides, the effect of parameters to objective was gained. The final result showed that this method which can improve the efficiency of ducted propeller and realize the motivation provided a new idea for propeller design.

Integrated Design Methodology for High-Precision/Speed Servomechanisms

2005 ◽  
Vol 219 (8) ◽  
pp. 843-852 ◽  
Author(s):  
M-S Kim ◽  
S-C Chung
Keyword(s):  
High Precision ◽  
Design Method ◽  
Integrated Design ◽  
Design Procedure ◽  
Optimization Method ◽  
Design Variables ◽  
Mechanical Subsystem ◽  
Speed Performance ◽  
Parametric Studies ◽  
Design Requirements

An integrated design method for a high-precision/speed servomechanism including interactions of mechanical and electrical subsystems is proposed in this article. On the basis of the multiobjective optimization method, a non-linear optimal design procedure of the mechanical subsystem is performed simultaneously through the design process of the electrical subsystem satisfying the desired performance. Mechanical and electrical constraints have been formulated according to design requirements. Both mechanical and electrical parameters are considered as design variables. Validity of the integrated design problem is verified on the different application areas. Parametric studies of the design variables have also been conducted in this article. Case studies show that the integrated design method for an x-y positioning system satisfies the desired high-precision/speed performance.

scholarly journals A Comprehensive Optimization Design Method of Aerodynamic, Acoustic, and Stealth of Helicopter Rotor Blades Based on Genetic Algorithm

2019 ◽  
Vol 2019 ◽  
pp. 1-12 ◽  
Author(s):  
Mingxu Yi ◽  
Yalin Pan ◽  
Jun Huang ◽  
Lifeng Wang ◽  
Dawei Liu
Keyword(s):  
Genetic Algorithm ◽  
Optimization Design ◽  
Design Method ◽  
Integrated Design ◽  
Optimization Method ◽  
Rotor Blades ◽  
Helicopter Rotor ◽  
Optimization Approach ◽  
Design Variables ◽  
Helicopter Rotor Blades

In this paper, a comprehensive optimization approach is presented to analyze the aerodynamic, acoustic, and stealth characteristics of helicopter rotor blades in hover flight based on the genetic algorithm (GA). The aerodynamic characteristics are simulated by the blade element momentum theory. And the acoustics are computed by the Farassat theory. The stealth performances are calculated through the combination of physical optics (PO) and equivalent currents (MEC). Furthermore, an advanced geometry representation algorithm which applies the class function/shape function transformation (CST) is introduced to generate the airfoil coordinates. This method is utilized to discuss the airfoil shape in terms of server design variables. The aerodynamic, acoustic, and stealth integrated design aims to achieve the minimum radar cross section (RCS) under the constraint of aerodynamic and acoustic requirement through the adjustment of airfoil shape design variables. Two types of rotor are used to illustrate the optimization method. The results obtained in this work show that the proposed technique is effective and acceptable.

scholarly journals Custom-Fit and Lightweight Optimization Design of Exoskeletons Using Parametric Conformal Lattice

2021 ◽  
pp. 129-138
Author(s):  
Fuyuan Liu ◽  
Min Chen ◽  
Lizhe Wang ◽  
Xiang Wang ◽  
Cheng-Hung Lo
Keyword(s):  
Lower Limb ◽  
Optimization Design ◽  
Design Method ◽  
Lightweight Design ◽  
Integrated Design ◽  
Element Analysis ◽  
Lower Limb Exoskeleton ◽  
Structural Framework ◽  
The Finite Element Analysis ◽  
Exoskeleton Design

AbstractThis paper presents an integrated design method for the customization and lightweight design of free-shaped wearable devices, illustrated by a lower limb exoskeleton. The customized design space is derived from the 3D scanning models. Based on the finite element analysis, the structural framework is determined through topology optimization with allowable strength. By means of generative design, the lattice library is constructed to fill the frames under different conformal algorithms. Finally, the proposed method is illustrated by the exoskeleton design case.

scholarly journals An efficient approach to reliability-based topology optimization for the structural lightweight design of planar continuum structures

2021 ◽  
Vol 37 ◽  
pp. 270-281
Author(s):  
Fangfang Yin ◽  
Kaifang Dang ◽  
Weimin Yang ◽  
Yumei Ding ◽  
Pengcheng Xie
Keyword(s):  
Topology Optimization ◽  
Lightweight Design ◽  
Integrated Design ◽  
Optimization Methods ◽  
Filter Function ◽  
Continuum Structures ◽  
Performance Indexes ◽  
Reliability Method ◽  
Economic Indexes ◽  
The Impact

Abstract In order to solve the application restrictions of deterministic-based topology optimization methods arising from the omission of uncertainty factors in practice, and to realize the calculation cost control of reliability-based topology optimization. In consideration of the current reliability-based topology optimization methods of continuum structures mainly based on performance indexes model with a power filter function. An efficient probabilistic reliability-based topology optimization model that regards mass and displacement as an objective function and constraint is established based on the first-order reliability method and a modified economic indexes model with a composite exponential filter function in this study. The topology optimization results obtained by different models are discussed in relation to optimal structure and convergence efficiency. Through numerical examples, it can be seen that the optimal layouts obtained by reliability-based models have an increased amount of material and more support structures, which reveals the necessity of considering uncertainty in lightweight design. In addition, the reliability-based modified model not only can obtain lighter optimal structures compared with traditional economic indexes models in most circumstances, but also has a significant advantage in convergence efficiency, with an average increase of 44.59% and 64.76% compared with the other two reliability-based models. Furthermore, the impact of the reliability index on the results is explored, which verifies the validity of the established model. This study provides a theoretical reference for lightweight or innovative feature-integrated design in engineering applications.

Optimization Research on Dynamic Balance of Spatial Engine under Limiting Shaking Moment

2009 ◽  
Vol 626-627 ◽  
pp. 693-698
Author(s):  
Yong Yong Zhu ◽  
S.Y. Gao
Keyword(s):  
Mathematical Model ◽  
Objective Function ◽  
Kinetic Analysis ◽  
Optimization Design ◽  
Design Method ◽  
Dynamic Balance ◽  
Optimized Design ◽  
Design Variables ◽  
The Mathematical Model ◽  
Shaking Moment

Dynamic balance of the spatial engine is researched. By considering the special wobble-plate engine as the model of spatial RRSSC linkages, design variables on the engine structure are confirmed based on the configuration characters and kinetic analysis of wobble-plate engine. In order to control the vibration of the engine frame and to decrease noise caused by the spatial engine, objective function is choosed as the dimensionless combinations of the various shaking forces and moments, the restriction condition of which presents limiting the percent of shaking moment. Then the optimization design is investigated by the mathematical model for dynamic balance. By use of the optimization design method to a type of wobble-plate engine, the optimization process as an example is demonstrated, it shows that the optimized design method benefits to control vibration and noise on the engines and improve the performance practically and theoretically.

A time-varying reliability-based robust design method considering overall efficiency of axial piston pump

2021 ◽  
pp. 1748006X2110661
Author(s):  
Zunling Du ◽  
Yimin Zhang
Keyword(s):  
Energy Conversion ◽  
Robust Design ◽  
Design Method ◽  
Design Stage ◽  
Structure Parameters ◽  
Time Varying ◽  
Design Variables ◽  
Reliability Method ◽  
Overall Efficiency ◽  
Axial Piston

Axial piston pumps (APPs) are the core energy conversion components in a hydraulic transmission system. Energy conversion efficiency is critically important for the performance and energy-saving of the pumps. In this paper, a time-varying reliability design method for the overall efficiency of APPs was established. The theoretical and practical instantaneous torque and flow rate of the whole APP were derived through comprehensive analysis of a single piston-slipper group. Moreover, as a case study, the developed model for the instantaneous overall efficiency was verified with a PPV103-10 pump from HYDAC. The time-variation of reliability for the pump was revealed by a fourth-order moment technique considering the randomness of working conditions and structure parameters, and the proposed reliability method was validated by Monte Carlo simulation. The effects of the mean values and variance sensitivity of random variables on the overall efficiency reliability were analyzed. Furthermore, the optimized time point and design variables were selected. The optimal structure parameters were obtained to meet the reliability requirement and the sensitivity of design variables was significantly reduced through the reliability-based robust design. The proposed method provides a theoretical basis for designers to improve the overall efficiency of APPs in the design stage.

Multivariate design and analysis of aircraft HEX under multiple working conditions within flight envelope

2021 ◽  
pp. 1-18
Author(s):  
Qihang Liu ◽  
G.Q. Xu ◽  
Jie Wen ◽  
Yanchen Fu ◽  
Laihe Zhuang ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Working Conditions ◽  
Design Method ◽  
Structural Parameters ◽  
Optimal Structure ◽  
Clear Correlation ◽  
Pressure Drops ◽  
Design Variables ◽  
Wide Range ◽  
Common Weight

Abstract This paper presents a multi-condition design method for the aircraft heat exchanger (HEX), marking with light weight, compactness and wide range of working conditions. The quasi-traversal genetic algorithm (QT-GA) method is introduced to obtain the optimal values of five structural parameters including the height, the tube diameter, the tube pitch, and the tube rows. The QT-GA method solves the deficiency of the conventional GA in the convergence, and gives a clear correlation between design variables and outputs. Pressure drops, heat transfer and the weight of the HEX are combined in a single objective function of GA in the HEX design, thus the optimal structure of the HEX suitable for all the working conditions can be directly obtained. After optimization, the weight of the HEX is reduced to 2.250 kg, more than 20% lower than a common weight of around 3 kg. Based on the optimal structure, the off-design performance of the HEX is further analyzed. Results show that the extreme working conditions for the heat transfer and the pressure drops are not consistent. It proves the advance of the multi-condition design method over traditional single-condition design method. In general, the proposed QT-GA design method is an efficient way to solve the multi-condition problems related to the aircraft HEX or other energy systems.

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