Additive manufacturing and topology optimization: A design strategy for a steering column mounting bracket considering overhang constraints

2020 ◽  
pp. 095440622091771
Author(s):  
Sara Mantovani ◽  
Giuseppe A Campo ◽  
Andrea Ferrari
Keyword(s):  
Finite Element ◽  
Topology Optimization ◽  
Additive Manufacturing ◽  
Isotropic Material ◽  
Element Model ◽  
The Body ◽  
Left Hand ◽  
Automotive Body ◽  
Body In White ◽  
Overhang Angle

In the present paper, the use of the topology optimization in a metal Additive Manufacturing application is discussed and applied to an automotive Body-in-White component called dash. The dash is in the front area of the Body-in-White, between the left-hand-side shock-tower and the Cross Car Beam, and its task is to support the steering column. The dash under investigation is an asymmetric rib-web aluminium casting part. The influence of Additive Manufacturing constraints together with modal and stiffness targets is investigated in view of mass reduction. The constraints drive the topology result towards a feasible and fully self-supporting Additive Manufacturing solution. A simplified finite element model of the steering column and of the Body-in-White front area is presented, and the limiting assumption of isotropic material for Additive Manufacturing is discussed. The optimization problem is solved with a gradient-based method relying on the Solid Isotropic Material with Penalization and on the RAtional Material with Penalization algorithms, considering the overhang angle constraint with given build directions. Three metals are tested: steel, aluminium and magnesium alloys. Topology optimization results with and without overhang angle constraints are discussed and compared. The aluminium solution, preferred for its lesser weight, has been preliminarily redesigned following the optimization results. The new dash concept has been validated by finite element considering stiffness, modal responses, and buckling resistance targets. The proposed dash design weighs 721 g compared to the 1537 g of the reference dash, with a weight reduction of 53%, for the same structural targets.

Model Analysis of Car’s Body-in-White Based on FEA

2011 ◽  
Vol 354-355 ◽  
pp. 454-457
Author(s):  
Yuan Wang ◽  
Li Xu ◽  
Xi Liang Dai ◽  
Sheng Hui Peng
Keyword(s):  
Finite Element ◽  
Optimal Design ◽  
Finite Element Model ◽  
Element Model ◽  
Model Analysis ◽  
The Body ◽  
Dynamic Parameters ◽  
Modal Test ◽  
Body In White ◽  
The Finite Element Model

In this paper, the finite element model of some car’s body-in-white is established in Hypermesh. The model analysis is executed based on the element model in ANSYS. Through the model analysis the dynamic parameters of the body-in-white are obtained. At the same time，the modal test of a real car body is implemented. The reliability of the finite element model is validated based on the modal test. The results show that the stiffness of the body-in-white is great enough and it can provide optimal design for future designers.

Finite element model updating of composite with adhesive jointed structure under built-up internal stress

2021 ◽  
pp. 107754632199358
Author(s):  
Ahmad Burhani Ahmad Basri ◽  
Dong Wook Chae ◽  
Hyeongill Lee
Keyword(s):  
Finite Element ◽  
Composite Structures ◽  
Model Updating ◽  
Local Stress ◽  
Element Model ◽  
The Body ◽  
Engineering Structures ◽  
Resonance Frequencies ◽  
Body In White ◽  
The Difference

Highly complex engineering structures such as the body-in-white of a car consist of hundreds of different parts that are assembled using various types of joints such as welded and adhesive joints. The finite element method has been used extensively in various engineering fields to predict and analyze the dynamic behavior of assembled structures. However, despite the use of well-characterized individual subcomponent models, the predicted results frequently differ from measured results. This is believed to be because of the invalid assumptions of the joint model such as the material properties and other uncertainties associated with the assembly. This study investigated the use of a model updating method (MSC Nastran SOL 200) to identify the invalid assumptions and uncertainties in adhesive jointed composite structures and to minimize the difference between predicted and measured results. Results revealed that the stresses built-up in a structure during the assembly process are permanently retained in the structure after the adhesive is completely cured and that they cause a local stress stiffening effect, which is believed to affect the resonance frequencies of the structure. Introducing the effect of the stresses as an updating parameter in the model updating process increases the prediction accuracy.

Component mode synthesis methods for a body-in-white noise and vibration analysis

2016 ◽  
Vol 231 (2) ◽  
pp. 279-288 ◽  
Author(s):  
Simone Vizzini ◽  
Magnus Olsson ◽  
Alessandro Scattina
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Element Model ◽  
The Body ◽  
Component Mode Synthesis ◽  
Synthesis Methods ◽  
Dynamic Substructuring ◽  
Reduction Methods ◽  
Body In White ◽  
Noise Vibration

In this work the dynamic substructuring approach was applied to a noise, vibration and harshness problem within the automotive engineering field. In particular, a noise, vibration and harshness analysis was carried out on the body-in-white structure of a passenger car. The work focuses on the theory of component mode synthesis. Two component mode synthesis reduction methods, namely the Craig–Bampton method and the Craig–Chang method, were applied to the body-in-white structure of the Volvo V40. The influences of various parameters were investigated. In particular, the effect of the reduction basis on the response accuracy and on the reduction time was studied. Moreover, the effects of the connection properties between different parts of the model were examined. The simulation times of the reduced models and of the full finite element model were compared. The results showed that the Craig–Chang method performs better when the modes are retained for up to one and a half times the maximum frequency response studied. Additionally, the Craig–Chang method gives a very accurate representation of the system dynamics even when connections with a low stiffness are used. Finally, it is possible to reduce the simulation time by up to 90% if component mode synthesis methods are used instead of the full finite element model.

The Concept modeling method: An approach to optimize the structural dynamics of a vehicle body

2020 ◽  
Vol 234 (13) ◽  
pp. 2923-2932 ◽  
Author(s):  
Mohammad Fard ◽  
Jianchun Yao ◽  
Richard Taube ◽  
John Laurence Davy
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Structural Dynamics ◽  
Element Model ◽  
Modeling Method ◽  
The Body ◽  
Vehicle Body ◽  
Concept Model ◽  
Body In White ◽  
Concept Modeling

Although the concept modeling method has already been proposed in the literature, there is still very limited knowledge about the validation and the application of this method for vehicle body design. This paper substantially increases this limited knowledge by developing a concept model for predicting and optimizing the structural dynamics of a vehicle body-in-white and validating this concept model against a detailed finite element model. The geometry and parameters of the concept model are extracted from its detailed finite element model. The major members and panels of the detailed finite element model are replaced by their equivalent beam and shell elements models. The joints of the concept model are represented by stiffness and mass matrices extracted from the detailed finite element model using the Guyan Reduction Method. The developed concept model is validated by comparing its structural dynamics, including the resonant frequencies and the vibration mode shapes, with the original detailed finite element model and the experimental results. The simplicity and small size of the concept model enable it to easily enhance the structural dynamics of the body-in-white by optimizing the cross-sections of the load-carrying members of the structure. The optimization in this case increased the resonant frequencies of the body-in-white while reducing the total mass by about 6 kg. The results prove that the concept modeling method can significantly enhance the body-in-white structural dynamics by reducing the complexity of the model and allowing the focus for the optimization to be on the main members of the structure at the development stage when the final design parameters are not well known and have not been fixed.

Topology Optimization Design of High Pressure Storage Tank Structure

2012 ◽  
Vol 430-432 ◽  
pp. 828-833
Author(s):  
Qiu Sheng Ma ◽  
Yi Cai ◽  
Dong Xing Tian
Keyword(s):  
Finite Element ◽  
High Pressure ◽  
Topology Optimization ◽  
Storage Tank ◽  
Optimization Design ◽  
Influence Factors ◽  
Element Model ◽  
Design Variables ◽  
Calculation Results ◽  
Pressure Storage

In this paper, based on ANSYS the topology optimization design for high pressure storage tank was studied by the means of the finite element structural analysis and optimization. the finite element model for optimization design was established. The design variables influence factors and rules on the optimization results are summarized. according to the calculation results the optimal design result for tank is determined considering the manufacturing and processing. The calculation results show that the method is effective in optimization design and provide the basis to further design high pressure tank.

Electric Bus Body Lightweight Design Based on Multiple Constrains

2012 ◽  
Vol 538-541 ◽  
pp. 3137-3144 ◽  
Author(s):  
Wen Wei Wang ◽  
Cheng Jun Zhou ◽  
Cheng Lin ◽  
Jiao Yang Chen
Keyword(s):  
Finite Element ◽  
Lightweight Design ◽  
Element Model ◽  
The Body ◽  
Body Frame ◽  
Electric Bus ◽  
Free Model ◽  
Bus Body ◽  
The Finite Element Model ◽  
Torsion Condition

The finite-element model of pure electric bus has been built and the free model analysis, displacement and stress analysis under bending condition and torsion condition have been conducted. Optimally design the pure electric bus frame based on multiple constrains. Reduce the body frame quality by 4.3% and meanwhile meet the modal and stress requirements.

New Hammerstein Modeling and Analysis for Controlling Melt Pool Width in Powder Bed Fusion Additive Manufacturing

2021 ◽  
pp. 1-7
Author(s):  
Dan Wang ◽  
Xinyu Zhao ◽  
Xu Chen
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Process Variations ◽  
Element Model ◽  
Hammerstein Model ◽  
Powder Bed Fusion ◽  
Modeling And Analysis ◽  
Powder Bed ◽  
Melt Pool ◽  
Linearized Model

Abstract Despite the advantages and emerging applications, broader adoption of powder bed fusion (PBF) additive manufacturing is challenged by insufficient reliability and in-process variations. Finite element modeling and control-oriented modeling have been identified fundamental for predicting and engineering part qualities in PBF. This paper first builds a finite element model (FEM) of the thermal fields to look into the convoluted thermal interactions during the PBF process. Using the FEM data, we identify a novel surrogate system model from the laser power to the melt pool width. Linking a linearized model with a memoryless nonlinear submodel, we develop a physics-based Hammerstein model that captures the complex spatiotemporal thermomechanical dynamics. We verify the accuracy of the Hammerstein model using the FEM and prove that the linearized model is only a representation of the Hammerstein model around the equilibrium point. Along the way, we conduct the stability and robustness analyses and formalize the Hammerstein model to facilitate the subsequent control designs.

An Improved Control Arm Design for a Commercial Vehicle

2021 ◽  
Author(s):  
Sinan Yıldırım ◽  
Ufuk Çoban ◽  
Mehmet Çevik
Keyword(s):  
Finite Element ◽  
Cost Effective ◽  
Element Model ◽  
Tensile Tests ◽  
The Body ◽  
Von Mises Stress ◽  
Driving Safety ◽  
Design Development ◽  
Element Analysis ◽  
Von Mises

Suspension linkages are one of the fundamental structural elements in each vehicle since they connect the wheel carriers i.e. axles to the body of the vehicle. Moreover, the characteristics of suspension linkages within a suspension system can directly affect driving safety, comfort and economics. Beyond these, all these design criteria are bounded to the package space of the vehicle. In last decades, suspension linkages have been focused on in terms of design development and cost reduction. In this study, a control arm of a diesel public bus was taken into account in order to get the most cost-effective design while improving the strength within specified boundary conditions. Due to the change of the supplier, the control arm of a rigid axle was redesigned to find an economical and more durable solution. The new design was analyzed first by the finite element analysis software Ansys and the finite element model of the control arm was validated by physical tensile tests. The outputs of the study demonstrate that the new design geometry reduces the maximum Von Mises stress 15% while being within the elastic region of the material in use and having found an economical solution in terms of supplier’s criteria.

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