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Cross-Section Optimization for Axial and Bending Crushes Using Dual Phase Steels
ISSN: 1946-3979, e-ISSN: 1946-3987
Published April 14, 2008 by SAE International in United States
Citation: Chen, G., Shi, M., and Tyan, T., "Cross-Section Optimization for Axial and Bending Crushes Using Dual Phase Steels," SAE Int. J. Mater. Manf. 1(1):537-547, 2009, https://doi.org/10.4271/2008-01-1125.
To achieve optimal axial and bending crush performance using dual phase steels for components designed for crash energy absorption and/or intrusion resistance applications, the cross sections of the components need to be optimized. In this study, Altair HyperMorph™ and HyperStudy® optimization software were used in defining the shape design variables and the optimization problem setup, and non-linear finite element code LS-DYNA® software was used in crush simulations. Correlated crash simulation models were utilized and the square cross-section was selected as the baseline. The optimized cross-sections for bending and axial crush performance resulted in significant mass and cost savings, particularly with the application of dual phase steels.