This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
A Case Study in Structural Optimization of an Automotive Body-In-White Design
Technical Paper
2008-01-0880
ISSN: 0148-7191, e-ISSN: 2688-3627
Annotation ability available
Sector:
Language:
English
Abstract
A process for simultaneously optimizing the mechanical performance and minimizing the weight of an automotive body-in-white will be developed herein. The process begins with appropriate load path definition though calculation of an optimized topology. Load paths are then converted to sheet metal, and initial critical cross sections are sized and shaped based on packaging, engineering judgment, and stress and stiffness approximations. As a general direction of design, section requirements are based on an overall vehicle “design for stiffness first” philosophy. Design for impact and durability requirements, which generally call for strength rather than stiffness, are then addressed by judicious application of the most recently developed automotive grade advanced high strength steels. Sheet metal gages, including tailored blanks design, are selected via experience and topometry optimization studies. Full-vehicle CAE analysis of the stiffness, durability and impact performance are then used to further refine the sheet metal design. In the next round of iteration, individual components of the body-in-white, such as the shock towers, are optimized using the aforementioned optimization tools and process. In all, using a generic mid-sized SUV body as a test case, it is demonstrated that in using this process, there exists the opportunity to reliably reduce the mass of a body-in-white structure by between 6 and 15 percent while still meeting stiffness, durability and impact goals.
Recommended Content
Authors
Citation
Baskin, D., Reed, D., Seel, T., Hunt, M. et al., "A Case Study in Structural Optimization of an Automotive Body-In-White Design," SAE Technical Paper 2008-01-0880, 2008, https://doi.org/10.4271/2008-01-0880.Also In
References
- Schmit L.A. “Structural Synthesis - Its Genesis and Development,” AIAA Journal 19 10 1981 1249 1263
- Schmit L.A. Farshi B. “Some Approximation Concepts for Structural Synthesis,” AIAA Journal 12 5 1974 692 699
- Vanderplaats G.N. Miura H. “Trends in Structural Optimization: Some Considerations in Using Standard Finite Element Software,” SAE Paper # 860801
- Vanderplaats G.N. “Automated Design Using Numerical Optimization,” SAE Paper # 791061
- Vanderplaats G.N. Salajegheh E. “An Efficient Approximation Technique for Frequency Constraints in Frame Optimization,” Int. J. for Num. Meth. In Eng. 26 1988 1057 1069
- Bendsoe M.P. Kikuchi N. “Generating Optimal Topologies in Structural Design Using a Homogenization Method,” Comp. Meth. In Appl. Mech. And Eng. 71 1988 197 224
- Laxman S. Mohan R. “Structural Optimization: Achieving a Robust and Light-Weight Design of Automotive Components,” SAE Paper # 2007-01-0794
- Soto C.A. “Structural Topology Optimization: From Minimizing Compliance to Maximizing Energy Absorption,” Int. J. Vehicle Design 25 1 2 2001 142 163
- Fredricson H. A. “Design for Property Based Optimization of Vehicle Body Structures,” SAE Paper # 2003-01-2755
- Nomura A. et al “Improvement of BIW NVH Characteristics Using a Concurrent Design Optimization Approach,” SAE Paper # 03NVC-322
- Fukushima J. Suzuki K. Kikuchi N. “Shape and Topology Optimization of a Car with Multiple Loading Conditions,” SAE Paper # 920777
- DaimlerChrysler AG Thyssen Krupp Stahl 2005
- Reed C. “Applications of Optistruct Optimization to Body In White Design,” Altair Engineering Coventry, England 2002