The effect of spotwelds and structural adhesives on static and dynamic characteristics of vehicle body design

2021 ◽  
pp. 095440702110044
Author(s):  
Gozde Tuncer ◽  
Deniz Mansouri ◽  
Polat Şendur
Keyword(s):  
Topology Optimization ◽  
Element Model ◽  
Vehicle Body ◽  
Functional Requirements ◽  
Performance Indices ◽  
Potential Cost ◽  
Vehicle Performance ◽  
Structural Adhesives ◽  
Body Design ◽  
Structural Adhesive

Spotwelding and structural adhesive applications are two important processes in the automotive industry as they are closely associated with the functional requirements, weight, and cost of the vehicle. Even though there is a vast body of literature on their mathematical models, the effect of these processes on key vehicle performance indices and optimization is rather limited. Besides, the weight benefit of these processes in terms of functional requirements has not been investigated. There are multiple objectives of the paper to fill this gap: (i) to quantify the effect of structural adhesives on the key performance indices (KPIs) of a vehicle body, (ii) to rank the components based on their gauge sensitivities for body KPIs using topometry optimization, (iii) to assess the weight impact of the structural adhesive applications using the gauge sensitivity results, (iv) to determine the optimum layout of the structural adhesive applications using topology optimization, (v) to present a methodology for automotive original equipment manufacturers (OEMs) to determine the “critical welds” on the vehicle body and reduce the number of spotwelds as a potential cost reduction action. For this purpose, a validated finite element model of 2010 Toyota Yaris has been used. Optimization of the structural adhesives and spotwelds was carried-out using SIMP (Solid Isotropic Material with Penalization) based topology optimization. The thickness of each panel is ranked using topometry optimization results. Automotive OEMs can use the proposed methodology to optimize the structural adhesives or spotwelding processes in their product development cycle.

Topology Optimization for the Light Rail Vehicle Body Based on Sub-Structure Technology

2013 ◽  
Vol 367 ◽  
pp. 145-150
Author(s):  
Jia Lian Cao ◽  
Jun Yong Li ◽  
Chao Yan Wan
Keyword(s):  
Topology Optimization ◽  
Large Scale ◽  
Volume Fraction ◽  
Element Model ◽  
Optimization Method ◽  
Practical Experience ◽  
Vehicle Body ◽  
Light Rail ◽  
Rail Vehicle ◽  
Technical Requirements

To complete the optimization of large-scale structure such as vehicle body efficiently, a new topology optimization method which combines with sub-structural analysis technology is proposed. With HyperWorks/Optistruct for a platform: first, the finite element model of the light rail vehicle body including sub-structure and non sub-structure is created; second, analyze the most dangerous condition using static reduction method which based on sub-structure technology, output the reduction matrix, generate the sub-structure; and then optimization model is defined including that design variables is the element density, objective function is the minimum volume fraction and constraint is the definition of stress, then enter the reduction matrix, and choose the non sub-structure area for topology optimization; Finally, based on the results, redesign the structure and get the improved one according to the technical requirements and practical experience.

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.

Discovering Sequenced Origami Folding Through Nonlinear Mechanics and Topology Optimization

2019 ◽  
Vol 141 (4) ◽  
Author(s):  
Andrew S. Gillman ◽  
Kazuko Fuchi ◽  
Philip R. Buskohl
Keyword(s):  
Topology Optimization ◽  
Design Space ◽  
Optimization Algorithms ◽  
Element Model ◽  
Evolutionary Optimization ◽  
Nonlinear Mechanics ◽  
Design Problems ◽  
Mechanics Model ◽  
Highly Nonlinear ◽  
Evolutionary Optimization Algorithms

Origami folding provides a novel method to transform two-dimensional (2D) sheets into complex functional structures. However, the enormity of the foldable design space necessitates development of algorithms to efficiently discover new origami fold patterns with specific performance objectives. To address this challenge, this work combines a recently developed efficient modified truss finite element model with a ground structure-based topology optimization framework. A nonlinear mechanics model is required to model the sequenced motion and large folding common in the actuation of origami structures. These highly nonlinear motions limit the ability to define convex objective functions, and parallelizable evolutionary optimization algorithms for traversing nonconvex origami design problems are developed and considered. The ability of this framework to discover fold topologies that maximize targeted actuation is verified for the well-known “Chomper” and “Square Twist” patterns. A simple twist-based design is also discovered using the verified framework. Through these case studies, the role of critical points and bifurcations emanating from sequenced deformation mechanisms (including interplay of folding, facet bending, and stretching) on design optimization is analyzed. In addition, the performance of both gradient and evolutionary optimization algorithms are explored, and genetic algorithms (GAs) consistently yield solutions with better performance given the apparent nonconvexity of the response-design space.

scholarly journals Topology Optimization of Vehicle B-Pillar

2021 ◽  
Vol 9 (11) ◽  
pp. 384-392
Author(s):  
Manas Metar
Keyword(s):  
Topology Optimization ◽  
Structural Optimization ◽  
Weight Reduction ◽  
Optimization Techniques ◽  
Vehicle Body ◽  
Element Analysis ◽  
Reduction Techniques ◽  
Roof Structure ◽  
Original Weight ◽  
3D Software

Abstract: Weight reduction techniques have been practiced by automobile manufacturers for the purpose of long range, less fuel consumption and achieving higher speeds. Due to the numerous set objectives that must be met, especially with respect to of car safety, automotive chassis design for vehicle weight reduction is a difficult task. In passenger classed vehicles using a monocoque chassis for vehicle construction has been a great solution for reducing overall wight of the vehicle body yet the structure is more stiffened and sturdier. However, some parts such as A-pillar, B-pillar, roof structure, floor pan can be further optimized to reduce more weight without affecting the strength needed for respective purposes. In this paper, the main focus is on reducing weight of the B-pillar. The B-pillar of a passenger car has been optimized using topology optimization and optimum weight reduction has been done. The modelling and simulation are done using SOLIDWORKS 3D software. The B-pillar in this study has been subjected to a static load of 140 KN. Further by providing goals and constraints the optimization was caried out. The results of Finite Element Analysis (FEA) of the original model are explained. The Topology Optimization resulted in reducing 53% of the original weight of the B-pillar. Keywords: Structural optimization techniques, weight reduction techniques, weight reduction technologies, need for weight reduction, Topology optimization, B-pillar design, structural optimization of B-pillar, Topology optimization of B-pillar.

A Sub-System Test Methodology for Simulating EEVC Side Impact

2000 ◽  
Author(s):  
Krishnakanth Aekbote ◽  
Srinivasan Sundararajan ◽  
Joseph A. Prater ◽  
Joe E. Abramczyk
Keyword(s):  
Full Scale ◽  
Test Method ◽  
Side Impact ◽  
Vehicle Body ◽  
Crash Test ◽  
Vehicle Performance ◽  
Test Methodology ◽  
Supporting Frame ◽  
The Impact ◽  
Crash Tests

Abstract A sled based test method for simulating full-scale EEVC (European) side impact crash test is described in this paper. Both the dummy (Eurosid-1) and vehicle structural responses were simulated, and validated with the full-scale crash tests. The effect of various structural configurations such as foam filled structures, material changes, rocker and b-pillar reinforcements, advanced door design concepts, on vehicle performance can be evaluated using this methodology at the early stages of design. In this approach, an actual EEVC honeycomb barrier and a vehicle body-in-white with doors were used. The under-hood components (engine, transmission, radiator, etc.), tires, and the front/rear suspensions were not included in the vehicle assembly, but they were replaced by lumped masses (by adding weight) in the front and rear of the vehicle, to maintain the overall vehicle weight. The vehicle was mounted on the sled by means of a supporting frame at the front/rear suspension attachments, and was allowed to translate in the impact direction only. At the start of the simulation, an instrumented Eurosid-1 dummy was seated inside the vehicle, while maintaining the same h-point location, chest angle, and door-to-dummy lateral distance, as in a full-scale crash test. The EEVC honeycomb barrier was mounted on another sled, and care was taken to ensure that weight, and the relative impact location to the vehicle, was maintained the same as in full-scale crash test. The Barrier impacted the stationary vehicle at an initial velocity of approx. 30 mph. The MDB and the vehicle were allowed to slide for about 20 inches from contact, before they were brought to rest. Accelerometers were mounted on the door inner sheet metal and b-pillar, rocker, seat cross-members, seats, and non-struck side rocker. The Barrier was instrumented with six load cells to monitor the impact force at different sections, and an accelerometer for deceleration measurement. The dummy, vehicle, and the Barrier responses showed good correlation when compared to full-scale crash tests. The test methodology was also used in assessing the performance/crashworthiness of various sub-system designs of the side structure (A-pillar, B-pillar, door, rocker, seat cross-members, etc.) of a passenger car. This paper concerns itself with the development and validation of the test methodology only, as the study of various side structure designs and evaluations are beyond the scope of this paper.

Shock Spectra of an Armored Vehicle With Cutouts Using ADINA

1993 ◽  
Author(s):  
Aaron D. Gupta ◽  
Henry L. Wisniewski
Keyword(s):  
Impact Load ◽  
Element Model ◽  
Global Response ◽  
Vehicle Performance ◽  
Performance Accuracy ◽  
Secondary Systems ◽  
Frequency Regime ◽  
Armored Vehicle ◽  
Nonlinear Components

Abstract Light combat vehicles are playing an important support role for both troops and other heavily armored combat vehicles. As such, they have a much greater risk than in previous roles of being subjected to transient loads such as impact and overpressure loads. Propagation of ballistic shock from an impacted region to the critical locations and attachment points for secondary systems can cause damage and misalignment to sensitive equipments contributing to malfunction and reduction of vehicle performance. Accuracy of determination of dynamic response of these vehicles is directly dependent on the degree of refinement of the generated model and how well the model incorporates the essential features of the vehicle and correlates to its important characteristics without being over-burdened by non-essential details. Additionally, response of nonlinear components of the vehicle in high frequency regime may influence the overall global response of the vehicle. As a result, hatch openings and access door cutouts with unsymmetric locations may have to be incorporated in the finite element model to allow fair comparison with first order experiments involving a stripped vehicle hull. The current study is an attempt to assess the influence of multiple rectangular cutouts on the overall transient response of a vehicle hull subjected to a side-on impact load.

scholarly journals A Study on the Relationship between the Design of Aerotrain and Its Stability Based on a Three-Dimensional Dynamic Model

Robotics ◽  
2020 ◽  
Vol 9 (4) ◽  
pp. 96
Author(s):  
Quang Huan Luong ◽  
Jeremy Jong ◽  
Yusuke Sugahara ◽  
Daisuke Matsuura ◽  
Yukio Takeda
Keyword(s):  
Dynamic Model ◽  
High Speed ◽  
Three Dimensional ◽  
Vehicle Body ◽  
Directional Stability ◽  
Rigid Body Model ◽  
Body Design ◽  
The Stability ◽  
New Generation ◽  
The Relationship

A new generation electric high-speed train called Aerotrain has levitation wings and levitates under Wing-in-Ground (WIG) effect along a U-shaped guideway. The previous study found that lacking knowledge of the design makes the prototype unable to regain stability when losing control. In this paper, the nonlinear three-dimensional dynamic model of the Aerotrain based on the rigid body model has been developed to investigate the relationship between the vehicle body design and its stability. Based on the dynamic model, this paper considered an Aerotrain with a horizontal tail and a vertical tail. To evaluate the stability, the location and area of these tails were parameterized. The effects of these parameters on the longitudinal and directional stability have been investigated to show that: the horizontal tail gives its best performance if the tail area is a function of the tail location; the larger vertical tail area and (or) the farther vertical tail location will give better directional stability. As for the lateral stability, a dihedral front levitation wing design was investigated. This design did not show its effectiveness, therefore a control system is needed. The obtained results are useful for the optimization studies on Aerotrain design as well as developing experimental prototypes.

Lightweight Design of the Welded Beam of Machining Center Based on Topology Optimization

2016 ◽  
Vol 836-837 ◽  
pp. 326-332
Author(s):  
Qin Sun ◽  
Zuo Li Li ◽  
Hui Yu ◽  
Yang Liu ◽  
Jin Sheng Zhang
Keyword(s):  
Topology Optimization ◽  
Natural Frequencies ◽  
Lightweight Design ◽  
Element Model ◽  
Machining Process ◽  
Mode Shapes ◽  
Cutting Condition ◽  
Machining Center ◽  
Maximum Stiffness ◽  
Stiffness Design

From the perspective of statics, the deformation of welded beam under the action of gravity and cutting force was studied in the paper. During the actual machining process, vibration of welded beam and even the machine can be caused due to the change of cutting condition and interference from the outside. To avoid the natural frequency, and prevent the occurrence of resonance phenomena, welded beam modal was further analyzed; the first six natural frequencies and mode shapes of the beam were achieved. Statics and modal analysis are the basis of lightweight design of the welded beam based on topology optimization. The topology optimization model of maximum stiffness design and eigenvalue problem structural dynamics was established. Finite element model of beam and its components was established in hypermesh, and the optimization objective function, constraint function and boundary conditions were also set. Compared with the structure before optimization, the weight of the beam was reduced 10%, the lightweight design of the welded beam was achieved and the comprehensive performance of the beam was significantly improved.

scholarly journals A topology optimization method of robot lightweight design based on the finite element model of assembly and its applications

2020 ◽  
Vol 103 (3) ◽  
pp. 003685042093648
Author(s):  
Liansen Sha ◽  
Andi Lin ◽  
Xinqiao Zhao ◽  
Shaolong Kuang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Topology Optimization ◽  
Lightweight Design ◽  
Element Model ◽  
Optimization Method ◽  
Maximum Displacement ◽  
Element Analysis ◽  
Upper Limb Exoskeleton ◽  
Topology Optimization Method

Topology optimization is a widely used lightweight design method for structural design of the collaborative robot. In this article, a topology optimization method for the robot lightweight design is proposed based on finite element analysis of the assembly so as to get the minimized weight and to avoid the stress analysis distortion phenomenon that compared the conventional topology optimization method by adding equivalent confining forces at the analyzed part’s boundary. For this method, the stress and deformation of the robot’s parts are calculated based on the finite element analysis of the assembly model. Then, the structure of the parts is redesigned with the goal of minimized mass and the constraint of maximum displacement of the robot’s end by topology optimization. The proposed method has the advantages of a better lightweight effect compared with the conventional one, which is demonstrated by a simple two-linkage robot lightweight design. Finally, the method is applied on a 5 degree of freedom upper-limb exoskeleton robot for lightweight design. Results show that there is a 10.4% reduction of the mass compared with the conventional method.

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