This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
A Tailor Welded Blanks Design of Automotive Front Rails by ESL Optimization for Crash Safety and Lightweighting
Technical Paper
2018-01-0120
ISSN: 0148-7191, e-ISSN: 2688-3627
This content contains downloadable datasets
Annotation ability available
Sector:
Language:
English
Abstract
Utilizing the tailor welded blanks (TWBs) design along with the latest AHSS grades for the front rails on a sedan was studied to reduce the weight of the vehicle and improve the crash safety performance. To find the most efficient material usage, the front rail parts were tailored into multiple blanks with varying thickness. A structural thickness optimization study of the tailored front rails was conducted for IIHS moderate overlap frontal crash, and the tailored blank thickness was set as design variable. The equivalent static loads (ESL) method was adopted for the thickness optimization, which allows many design variables to be optimized simultaneously. The torsion and bending stiffness of the sedan body in prime were set as design constraints, and would not be compromised. The optimal thickness configurations of the TWB designs by ESL optimization suggest that the weight of the frontal rails can be reduced by more than 30% while still maintaining the crash safety performance. These TWB designs were validated by US-NCAP full frontal impact and show similar performance with baseline. A 3rd gen AHSS, NEXMET™1000, was selected on four parts of the front rails to replace the baseline HSLA350. The optimal tailored frontal rail design using NEXMET™1000 grade was obtained through ESL thickness optimization and validated by US-NCAP full frontal impact. Compared with HSLA350, the NEXMET™1000 grade offers better crash safety performance with more weight reduction potential.
An optimal thickness coefficient is proposed in this study to evaluate the material efficiency of the tailored blanks and the amount of thickness changes required for each blank to reach the most efficient material usage. The optimal TWB thickness configurations for HSLA350 and NEXMET™1000 grades through ESL were evaluated using this optimal thickness coefficient. The critical locations on front rails for crash safety were identified and the amount of thickness changes needed characterized. The tailor welded blanks technology can be implemented in the front rail design to reduce weight and improve crash safety. This optimal thickness coefficient can guide the automotive design for lightweighting.
Recommended Content
Authors
Citation
Liang, J., Powers, J., and Stevens, S., "A Tailor Welded Blanks Design of Automotive Front Rails by ESL Optimization for Crash Safety and Lightweighting," SAE Technical Paper 2018-01-0120, 2018, https://doi.org/10.4271/2018-01-0120.Data Sets - Support Documents
| Title | Description | Download |
|---|---|---|
| Unnamed Dataset 1 | ||
| Unnamed Dataset 2 |
Also In
References
- Tamareli , C.M. AHSS101- The Evolving Use of Advanced High-Strength Steels for Automotive Applications Southfield, Michigan, USA Steel Market Development Institute 2011
- Morgans , S. 2011
- Grabowski , T. May 2014
- Keeler , S. and Kimchi , M. Advanced High Strength Steels Application Guidelines Version 5.0 Brussels WorldAutoSteel 2014
- Coakley , D. and Zischke , J. May 2014
- Swartzell , T. A. May 2016
- Furusako , S. , Uenishi , A. and Miyazaki , Y. 2007
- Kuziak , R. , Kawalla , R. , and Waengler , S. Advanced High Strength Steels for Automotive Industry Archives of Civil and Mechanical Engineering 8 2 103 117 2008
- Matlock , D. , Speer , J. , De Moor , E. , and Gibbs , P. Recent Developments in Advanced High Strength Sheet Steels for Automotive Applications: An Overview JESTECH 15 1 1 12 2012
- Tisza , M. Advanced Materials for Automotive Application IOP Conference Series: Materials Science and Engineering 47 012010 2013 10.1088/1757-899X/47/1/012010
- Nakagaito , T. , Matsuoka , S. , Kaneko , S. , Kawasaki , Y. et al. July 2014
- Thomas , G. and Garza-Martinez , L. Nov 2014
- Powers , J. , Thomas , G. , Gill , A. and Case , E. AK Steel’s Development of AHSS Steel Grades for Body Structures and Their Applications 2016
- Petersen , E. May 2016
- Vanderplaats , G.N. Thirty Years of Modern Structural Optimization Advances in Engineering Software 16 2 81 88 1993
- Bendsoe , M.P. Optimization of Structural Topology, Shape, and Material Berlin, Heidelberg Springer 1995 10.1007/978-3-662-03115-5
- Bobaru , F. and Mukherjee , S. Shape Sensitivity Analysis and Shape Optimization in Planar Elasticity Using the Element-Free Galerkin Method Computer Methods in Applied Mechanics and Engineering 190 32-33 4319 4337 2001
- Eschenauer , H.A. and Olhoff , N. Topology Optimization of Continuum Structures: A Review Applied Mechanics Reviews 54 4 331 390 2001
- Tanskanen , P. The Evolutionary Structural Optimization Method: Theoretical Aspects Computer Methods in Applied Mechanics and Engineering 191 47-48 5485 5498 2002
- Leiva , J. P. , Watson , B. C. and Kosaka , I. 2007
- Ide , T. , Otomori , M. , Leiva , J.P. , and Watson , B.C. Structural Optimization Methods and Techniques to Design Light and Efficient Automatic Transmission of Vehicles with Low Radiated Noise Structural and Multidisciplinary Optimization 50 6 1137 1150 2014
- Hassani , B. , Tavakkoli , S.M. , and Ghasemnejad , H. Simultaneous Shape and Topology Optimization of Shell Structures Structural and Multidisciplinary Optimization 48 1 221 233 2013
- Guo , X. and Cheng , G. Recent Development in Structural Design and Optimization Acta Mechanica Sinica 26 807 823 2010
- Lee , Y. , Ahm , J. and Park , G. th June 2015
- Craig , K.J. , Stander , N. , Dooge , D.A. , and Varadappa , S. Automotive Crashworthiness Design Using Response Surface Based Variable Screening and Optimization Engineering Computations 22 1 38 61 2005 10.1108/02644400510572406
- Venter , G. , Haftka , R.T. , and Starnes , J.H. Construction of Response Surface Approximations for Design Optimization AIAA Journal 36 12 2242 2249 1998
- Jeong , S.B. , Yi , S.I. , Kan , C.D. , Nagabhushana , V. et al. Structural Optimization of an Automobile Roof Structure Using Equivalent Static Loads Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering 222 11 1985 1995 2008
- Lee , H. A. and Park , G. J. May 2013
- Genest , L. , Jézéquel , L. , Gillot , F. and Mercier , F. Jun 2015
- Jang , H. H. and Lee , H. A. Dynamic Response Topology Optimization in the Time Domain Using Equivalent Static Loads 52nd AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics and Materials Conference Denver, Colorado Apr 2011
- Yi , S.I. , Lee , H.A. , and Park , G.J. Optimization of a Structure with Contact Conditions Using Equivalent Loads Journal of Mechanical Science and Technology 25 3 773 782 2011 10.1007/s12206-011-0129-1
- Christensen , J. , Bastien , C. , and Blundell , M.V. The Feasibility of ESLM for BIW Roof Structure Development and Optimization Journal of Mathematical Research and Applications 1 2 34 47 2013
- Kinsey , B. , Liu , Z. , and Cao , J. A Novel Forming Technology for Tailor-Welded Blanks Journal of Materials Processing Technology 99 1-3 145 153 2000
- Bhaskar , V.V. , Narayanan , R.G. , and Narasimhan , K. Effect of Thickness Ratio on Formability of Tailor Welded Blanks AIP Conference Proceedings 712 863 2004
- Safdarian , R. , Jorge , R.M.N. , Santos , A.D. , Naeini , H.M. et al. A Comparative Study of Forming Limit Diagram Prediction of Tailor Welded Blanks International Journal of Material Forming 8 2 293 304 2015
- Hirt , G. , Abratis , C. , and Ames , J. Manufacturing of Sheet Metal Parts from Tailor Rolled Blanks Journal for Technology of Plasticity 30 1 2005
- Zoernack , M. Material Related Design with Tailor Rolled Products May 2016
- iihs.org 2017
- Chan , S.M. , Chan , L.C. , and Lee , T.C. Tailor-Welded Blanks of Different Thickness Ratios Effects on Forming Limit Diagrams Journal of Material Processing Technology 132 1-3 95 101 2003
- Riahi , M. and Amini , A. Effect of Different Combinations of Tailor-Welded Blank Coupled with Change in Weld Location on Mechanical Properties by Laser Welding The International Journal of Advanced Manufacturing Technology 67 5-8 1937 1945 2013