白车身扭转刚度分析与优化

对某白车身建立有限元模,利用MSC Nastran软件进行扭转刚度和模态分析,在此基础上以车身重量为优化目标,在满足扭转刚度要求的条件下对零件厚度进行敏感度分析和优化分析,得到了符合设计要求的改进方案.     

基于灵敏度分析的白车身扭转刚度优化

为提高某量产车型白车身(Body in White,BIW)扭转刚度,提出一种基于灵敏度分析的BIW刚度优化方法.深入阐述灵敏度分析原理和车身刚度优化策略,分析该车型车身开发中的37个低成本横向构件的料厚变化对BIW扭转刚度的影响.通过对BIW有限元模型的计算和分析,验证优化策略并对比优化前后的BIW扭转刚度性能.结果表明该方法以较低成本就可达到车身扭转刚度的较大提高.     

参数化白车身结构轻量化多目标优化

利用SFE Concept建立某轿车白车身的参数化模型,采用有限元法对白车身的静态弯曲和扭转刚度、主要低阶模态进行分析,并将仿真结果与试验结果进行对比。将参数化白车身与动力总成、底盘、闭合件连接后,仿真分析整车正面100%碰撞安全性能并验证有限元模型的有效性。提出通过相对灵敏度分析确定白车身非安全件设计变量的方法,采用最优拉丁超立方方法生成样本点,基于径向基神经网络方法拟合近似模型,以白车身非安全件和正碰安全件为轻量化对象,通过第二代非劣排序遗传算法对白车身进行多目标优化设计。结果表明：在白车身静态弯曲刚度降低3.60%、静态扭转刚度降低3.91%、一阶弯曲模态固有频率降低0.09%、一阶扭转模态固有频率上升1.26%、正碰安全性能基本不变的情况下,白车身质量减少24.17 kg,减重7.42%,轻量化效果显著。     

基于隐式参数化的车身多学科轻量化设计

为实现整车综合性能的快速方案验证和优化设计,在新车型设计阶段构建车身隐式参数化模型,并对其进行模态、刚度和安全等综合性能计算,验证参数化模型的有效性。基于灵敏度分析、试验设计（design of experiments, DOE）方法和近似模型优化等策略,对某白车身进行多学科轻量化设计。优化设计结果表明,白车身的模态、刚度和安全性能均满足设计要求。     

PIAnO在白车身轻量化设计上的应用

以某SUV车型的白车身为研究对象,采用高效的实验设计和优化软件PIAnO,综合考虑其模态、刚度、40%偏置碰和侧碰等性能进行轻量化设计。确定并优化设计变量,对白车身刚度和模态性能进行近似建模。提出分段优化方案并进行仿真验证,得到的白车身质量减少11.93 kg,下降3.08%。将该轻量化白车身的100%正碰、强度、IPI和NTF性能进行验证,满足设计要求,证明基于PIAnO的白车身轻量化策略行之有效。     

基于隐式参数化耦合模型的车身集成优化

为提高车身截面优化效率,基于SFE CONCEPT构建白车身关注部位的隐式参数化模型,并与白车身有限元非参数化模型进行耦合,使参数化模型与有限元模型耦合边界处的连接关系随截面变化自动更新,通过试验验证耦合模型的有效性。基于试验设计（design of experiments, DOE）方法、近似模型、多目标优化等策略,对白车身耦合模型进行刚度和模态等多学科集成优化,实现车身局部结构快速轻量化设计。     

非承载式SUV白车身结构分析及优化

以某全新开发的SUV非承载式车身为研究对象,建立V91车身有限元模型,并进行模态分析.为使车身1阶模态满足目标值要求,对车身进行灵敏度分析和截面刚度分析,并提出改进方案.经过优化,车身的1阶弯曲模态提升7.8%,1阶扭转模态提升25.7%.研究结果可为企业研发非承载式SUV车身提供参考.     

多目标轻量化的白车身隐式参数数值模拟

普通方法构建的白车身多目标轻量化设计模型存在精准度低、优化效果差的问题.通过隐式参数数值模拟方法,先对白车身构建隐式参数化模型,再通过非安全件轻量化优化设计和正面碰撞安全件轻量化优化设计实现白车身多目标轻量化.通过对该方法的性能优化验证及对比实验发现,经过多次迭代后,上述方法构建的白车身模型的精准度均大于90％,优化变化率大于8％.     

汽车车身静态刚度测量

针对目前我国汽车车身刚度检测设备的落后现状,采用现代微机检测与控制技术开发了一种新型的汽车车身静态刚度测量系统;该系统采用精密测量技术,用DSP2407采集多路数据,并利用工业控制计算机进行数据处理,在线检测汽车车身的刚度状况并以红旗轿车为例,对其白车身进行弯曲变形和扭转变形试验,检测汽车车身的刚度状况;该项目填补了全自动检测汽车车身静态刚度的空白,为国内首创.     

摩托车车架模态、刚度Nastran优化实例

本文采用有限元结构分析软件Nastran对摩托车车架的模态、刚度进行优化,计算各个设计变量的灵敏度系数,并结合工程实际,找出了对车架第一阶模态频率和弯曲、扭转刚度值影响最大的因素。     

FSC方程式赛车单体壳车架设计

车架质量占赛车整车质量的比例很大,其在轻量化方面存在可优化空间。利用CATIA设计一种钢管桁架结构和单体壳结构的复合式车架,在HyperMesh中建立有限元模型,对车架的单体壳部分进行尺寸优化,确定不同区域层合板的最佳厚度,最终得到的车架质量为21.8 kg,扭转刚度为4 057 N·m/(°),较纯钢管车架减重约5 kg,刚度提高约1倍,满足设计目标。     

Lightweight flatbed trailer design by using topology and thickness optimization

A new design for a lightweight flatbed trailer with high bending stiffness and torsional frequency is presented. The design procedure consists of two main steps: topology optimization and thickness optimization. During topology optimization, a creative frame layout different from existing ladder-type frames can be obtained by searching the best layout out of all possible layouts of a simplified design domain model. After approximating the result of topology optimization as a thin-walled structure, the approximated thicknesses of the plates are optimized to minimize the mass of a trailer. The bending stiffness and torsional frequency obtained by topology optimization are set as design constraints for thickness optimization. Due to the closed cross-section, the optimized trailer can efficiently increase the stiffness-to-mass ratio to a large extent. Discrete thicknesses are employed as design variables for thickness optimization so that the thicknesses of the plates of a trailer can be included in those of commercially available high-strength steel products. The final model has a 29% reduction in total mass, a 21% decrease in mean compliance with a uniform bending load, and a 169% increase in torsional frequency.     

Multi-objective optimization for bus body with strength and rollover safety constraints based on surrogate models

It is important to consider the performances of lightweight, stiffness, strength and rollover safety when designing a bus body. In this paper, the finite element (FE) analysis models including strength, stiffness and rollover crashworthiness of a bus body are first built and then validated by physical tests. Based on the FE models, the design of experiment is implemented and multiple surrogate models are created with response surface method and hybrid radial basis function according to the experimental data. After that, a multi-objective optimization problem (MOP) of the bus body is formulated in which the objective is to minimize the weight and maximize the torsional stiffness of the bus body under the constraints of strength and rollover safety. The MOP is solved by employing multi-objective evolutionary algorithms to obtain the Pareto optimal set. Finally, an optimal solution of the set is chosen as the final design and compared with the original design.     

Automotive door design with the ULSAB concept. using structural optimization

Weight reduction for an automobile body is sought to achieve fuel efficiency and energy conservation. Recently, the UltraLight Steel Auto Body (ULSAB) concept is suggested using a few methods. ULSAB pursues a lightweight automotive with steel structure. Tailor welded blank (TWB) is one of the ULSAB methods and TWB can be utilized for an automobile door. Optimization technology is applied to the inner panel of a door which is made by TWB. A design process is appropriately defined for the inner panel. The design starts from an existing component. At first, the inner reinforcements are removed to use TWB technology. In the conceptual design stage, topology optimization is conducted to find the distribution of the variable thickness. The number of parts and the welding lines are determined from the topology design. In the detailed design process, size optimization is carried out to find thickness while the stiffness constraints are satisfied. Size optimization is performed based on the welding lines determined from topology optimization. The final parting lines are tuned by shape optimization. The results from size optimization are considered constant in shape optimization. A commercial optimization software GENESIS is utilized for the optimization processes. Received November 10, 2000     

Evolutionary structural optimization for stress minimization problems by discrete thickness design

Stress minimization is a major aspect of structural optimization in a wide range of engineering designs. This paper presents a new evolutionary criterion for the problems of variable thickness design whilst minimizing the maximum stress in a structure. On the basis of finite element analysis, a stress sensitivity number is derived to estimate the stress change in an element due to varying the thickness of other elements. Following the evolutionary optimization procedure, an optimal design with a minimum maximum stress is achieved by gradually removing material from those elements, which have the lowest stress sensitivity number or adding material onto those elements, which have the highest stress sensitivity number. The numerical examples presented in this paper demonstrate the capacity of the proposed method for solving stress minimization problems. The results based on the stress criterion are compared with traditional ones based on a stiffness criterion, and an optimization scheme based on the combination of both the stress minimization and the stiffness maximization criteria is presented.