SHAPE OPTIMIZATION OF THREE-DIMENSIONAL STAMPED AND SOLID AUTOMOTIVE COMPONENTS

The shape optimization of realistic, three-dimensional automotive components is discussed, stressing the integration of the major parts of the total process—modeling, mesh generation, finite element and sensitivity analysis, and optimization. Stamped and solid components are treated separately. For stamped parts, a highly automated capability has been developed; the problem description is based upon a parameterized boundary design element concept for the definition of the geometry. Automatic triangulation and adaptive mesh refinement are used to provide an automated analysis capability which requires only boundary data and takes into account sensitivity of the solution accuracy to boundary shape. For solid components, a general extension of the two- dimensional boundary design element concept has not been achieved. In this case the parameterized surface shape is provided by using a generic modeling concept based upon isoparametric mapping patches which also serve as the mesh generator. Emphasis is placed upon the coupling of optimization with a commercially available finite element program. To combine these, it is necessary to modularize the program architecture and to obtain shape design sensitivities using the material derivative approach so that only boundary solution data are needed. Several realistic component designs demonstrate the effectiveness of both capabilities.

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