Lightweight design of bus frames from multi-material topology optimization to cross-sectional size optimization

ABSTRACT A comprehensive solution for bus frame design is proposed to bridge multi-material topology optimization and cross-sectional size optimization. Three types of variables (material, topology and size) and two types of constraints (static stiffness and frequencies) are considered to promote this practical design. For multi-material topology optimization, an ordered solid isotropic material with penalization interpolation is used to transform the multi-material selection problem into a pure topology optimization problem, without introducing new design variables. Then, based on the previously optimal topology result, cross-sectional sizes of the bus frame are optimized to further seek the least mass. Sequential linear programming is preferred to solve the two structural optimization problems. Finally, an engineering example verifies the effectiveness of the presented method, which bridges the gap between topology optimization and size optimization, and achieves a more lightweight bus frame than traditional single-material topology optimization.

[1]  Mahmoud Abdelhamid,et al.  Using Quality Function Deployment and Analytical Hierarchy Process for material selection of Body-In-White , 2011 .

[2]  Anders Klarbring,et al.  Structural optimization of modular product families with application to car space frame structures , 2006 .

[3]  Wenjie Zuo,et al.  Stress sensitivity analysis and optimization of automobile body frame consisting of rectangular tubes , 2016 .

[4]  Abdelhamid Chriette,et al.  A survey of multidisciplinary design optimization methods in launch vehicle design , 2012 .

[5]  Yongsheng Ma,et al.  Multi-material plastic part design via the level set shape and topology optimization method , 2016 .

[6]  Wenjie Zuo,et al.  Component sensitivity analysis of conceptual vehicle body for lightweight design under static and dynamic stiffness demands , 2014 .

[7]  M. Bendsøe,et al.  Topology Optimization: "Theory, Methods, And Applications" , 2011 .

[8]  Wenjie Zuo,et al.  An object-oriented graphics interface design and optimization software for cross-sectional shape of automobile body , 2013, Adv. Eng. Softw..

[9]  A. Ramani.  Multi-material topology optimization with strength constraints , 2011 .

[10]  Eugenio Guglielmino,et al.  Structural optimization of a motorcycle chassis by pattern search algorithm , 2017 .

[11]  B. L. Boada,et al.  Torsional stiffness and weight optimization of a real bus structure , 2010 .

[12]  M. Bendsøe,et al.  Material interpolation schemes in topology optimization , 1999 .

[13]  N. Xiao,et al.  An efficient lightweight design strategy for body-in-white based on implicit parameterization technique , 2017 .

[14]  Masataka Yoshimura,et al.  Structural optimization based on topology optimization techniques using frame elements considering cross-sectional properties , 2007 .

[15]  Anand Ramani,et al.  A pseudo-sensitivity based discrete-variable approach to structural topology optimization with multiple materials , 2010 .

[16]  Anders Klarbring,et al.  Conceptual optimal design of modular car product families using simultaneous size, shape and topology optimization , 2007 .

[17]  Nianfeng Wang,et al.  Hierarchical optimization for topology design of multi-material compliant mechanisms , 2017 .

[18]  K. Lee,et al.  The harmony search heuristic algorithm for discrete structural optimization , 2005 .

[19]  Wenjie Zuo,et al.  Cross-sectional shape optimisation for thin-walled beam crashworthiness with stamping constraints using genetic algorithm , 2017 .

[20]  Xu Guo,et al.  Explicit three dimensional topology optimization via Moving Morphable Void (MMV) approach , 2017, 1704.06060.

[21]  Ren-Jye Yang,et al.  Optimization of car body under constraints of noise, vibration, and harshness (NVH), and crash , 2000 .

[22]  G. K. Ananthasuresh,et al.  Topology optimization of compliant mechanisms with multiple materials using a peak function material interpolation scheme , 2001 .

[23]  José Pedro Albergaria Amaral Blasques,et al.  Multi-material topology optimization of laminated composite beams with eigenfrequency constraints , 2014 .

[24]  Masataka Yoshimura,et al.  Concurrent Design and Evaluation Based on Structural Optimization using Structural and Function-oriented Elements at the Conceptual Design Phase , 2005, Concurr. Eng. Res. Appl..

[25]  Tomasz Kuczek,et al.  Application of manufacturing constraints to structural optimization of thin-walled structures , 2016 .

[26]  Enying Li,et al.  A multiple-GPU based parallel independent coefficient reanalysis method and applications for vehicle design , 2015, Adv. Eng. Softw..

[27]  Tadeusz Uhl,et al.  MULTI-MATERIAL DESIGN OPTIMIZATION OF A BUS BODY STRUCTURE , 2013 .

[28]  Nong Zhang,et al.  Level-set topology optimization for multimaterial and multifunctional mechanical metamaterials , 2017 .

[29]  Shuang Wang,et al.  Lightweight optimization of the side structure of automobile body using combined grey relational and principal component analysis , 2017 .

[30]  F Lan,et al.  Comparative analysis for bus side structures and lightweight optimization , 2004 .

[31]  J. Sobieszczanski-Sobieski,et al.  Optimization of car body under constraints of noise, vibration, and harshness (NVH), and crash , 2001 .

[32]  K. Lee,et al.  A new meta-heuristic algorithm for continuous engineering optimization: harmony search theory and practice , 2005 .

[33]  Wenjie Zuo,et al.  Bi-level optimization for the cross-sectional shape of a thin-walled car body frame with static stiffness and dynamic frequency stiffness constraints , 2015 .

[34]  Xu Guo,et al.  Structural complexity control in topology optimization via moving morphable component (MMC) approach , 2017 .

[35]  K. Saitou,et al.  Multi-material topology optimization using ordered SIMP interpolation , 2016, Structural and Multidisciplinary Optimization.

[36]  Hu Wang,et al.  A Parallel Reanalysis Method Based on Approximate Inverse Matrix for Complex Engineering Problems , 2013 .