Automating Parametric Redesign of Structural Thinwalled Frames from Topology Optimization Results

This presentation recording was made at NAFEMS Americas Seminar "Engineering Analysis & Simulation in the Automotive Industry: Creating the Next Generation Vehicle Accurate Modelling for Tomorrow's Technologies".

The automotive engineering community is now confronting the largest technology transformation since its inception. This includes the electrification of powertrains for more efficient consumption and cleaner emissions, the reinvention of the battery with fast wireless charging capabilities and finally the advent of a fully autonomous vehicle. Compounding to these technology changes, the automotive companies design verification process is moving away from a major reliance on physical testing to almost a full virtual simulation product verification process. The challenges to the automotive engineers are enormous and require a significant increase in the upfront use of numerical simulation capabilities, methods and processes such they’re able to efficiently design, manufacture and deliver these very innovative technologies to the market in greater speeds than ever before.)

Resource Abstract

With the increasing demand for a shorter lifecycle of automotive production to stay competitive in the field, automotive manufacturers often share the components of the newer models closely with the related product families or previous generations. Combined with the constant push from the US regulations for higher fuel efficiency automotive manufactures are actively looking at different approaches to design and manufacture light weight vehicles while maintaining their crashworthiness. Driven by these two motivations, in this paper, we proposed the methodology of automating the parametric redesign of structural thin wall frames using topology optimization results.

Generally, in the process of designing an automobile, the stylists will first develop a conceptual design, together with the interior and exterior packaging of the vehicle. Then, designers will optimize the topology of the Body In White (BIW) at the component level before moving on to Finite Element Analysis (FEA) and crash simulation and eventually the final design of the vehicle. Usually, due to the complexity of the of the vehicle model, the computation time to run the FEA and crash simulation is very high. In this research the topology optimization of the BIW is used to design new lighter structures by looking at the cross-sectional properties of the topology optimization results and matching them with properties of a new sheet-metal part’s cross sectional design in the allowable design space.

Document Details

AuthorWang. L
TypePresentation Recording
Date 8th November 2018
OrganisationThe Ohio State University


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