Simplified crashworthiness method of automotive frame for conceptual design

Abstract The crashworthiness design of automotive structure is crucial to ensure the safety of passengers. Lumped parameter models, multi-body models, plastic frame models and detailed shell element models were all introduced to simulate the collision process of automotive structure. However, plastic frame models were only confined to use box beams. Therefore, this paper presents a comprehensive crashworthiness design of plastic frame model, which can innovatively create complex thin-walled beams with arbitrary cross-sectional shapes, such as open, single-cell, double-cell, three-cell and four-cell sections. Numerical example verified that the proposed model can effectively replace detailed shell element model to accelerate the crashworthiness analysis of automotive structure, especially for the conceptual design.

[1]  Javad Marzbanrad,et al.  Crashworthiness study of a full vehicle-lumped model using parameters optimisation , 2015 .

[2]  Dušan Kecman,et al.  Bending collapse of rectangular and square section tubes , 1983 .

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

[4]  Masataka Yoshimura,et al.  A Multiple Cross-Sectional Shape Optimization Method for Automotive Body Frames , 2005 .

[5]  Tomasz Wierzbicki,et al.  Effect of an Ultralight Metal Filler on the Torsional Crushing Behaviour of Thin-Walled Prismatic Columns , 1997 .

[6]  Tongxi Yu,et al.  AXIAL CRUSHING OF TRIANGULAR TUBES , 2013 .

[7]  O. Hopperstad,et al.  Aluminum foam-filled extrusions subjected to oblique loading: experimental and numerical study , 2004 .

[8]  T. Wierzbicki,et al.  On the Crushing Mechanics of Thin-Walled Structures , 1983 .

[9]  T. Belytschko,et al.  Large displacement, transient analysis of space frames , 1977 .

[10]  D. Thambiratnam,et al.  Dynamic simulation and energy absorption of tapered thin-walled tubes under oblique impact loading , 2006 .

[11]  Jianguang Fang,et al.  Parameterization of criss-cross configurations for multiobjective crashworthiness optimization , 2017 .

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

[13]  Qing Li,et al.  Bending characteristics of top-hat structures through tailor rolled blank (TRB) process , 2018 .

[14]  Yucheng Liu.  Crashworthiness design of thin-walled curved beams with box and channel cross sections , 2010 .

[15]  José G. Dias,et al.  A road vehicle multibody model for crash simulation based on the plastic hinges approach to structural deformations , 2007 .

[16]  Guangyong Sun,et al.  Energy absorption mechanics for variable thickness thin-walled structures , 2017 .

[17]  Hu Wang,et al.  Time-based metamodeling technique for vehicle crashworthiness optimization , 2010 .

[18]  Yucheng Liu,et al.  Bending collapse of thin-walled circular tubes and computational application , 2008 .

[19]  A. Asanjarani,et al.  Multi-objective crashworthiness optimization of tapered thin-walled square tubes with indentations , 2017 .

[20]  Xiong Zhang,et al.  Axial crushing and optimal design of square tubes with graded thickness , 2014 .

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

[22]  Abdul-Ghani Olabi,et al.  On the crashworthiness performance of thin-walled energy absorbers: Recent advances and future developments , 2017 .

[23]  Jianguang Fang,et al.  Dynamic crashing behavior of new extrudable multi-cell tubes with a functionally graded thickness , 2015 .

[24]  Jorge Ambrósio,et al.  Identification of multibody vehicle models for crash analysis using an optimization methodology , 2010 .

[25]  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 .

[26]  Guangyao Li,et al.  Crashworthiness optimization of foam-filled tapered thin-walled structure using multiple surrogate models , 2013 .

[27]  Javad Marzbanrad,et al.  Analytical and experimental studies on quasi-static axial crush behavior of thin-walled tailor-made aluminum tubes , 2012 .

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

[29]  Hirad Assimi,et al.  Sizing and topology optimization of truss structures using genetic programming , 2017, Swarm Evol. Comput..

[30]  T Wierzbicki,et al.  Quasi-static crushing of S-shaped aluminum front rail , 2004 .

[31]  O. Hopperstad,et al.  Static and dynamic crushing of square aluminium extrusions with aluminium foam filler , 2000 .

[32]  Tomasz Wierzbicki,et al.  Crash behavior of box columns filled with aluminum honeycomb or foam , 1998 .

[33]  Qing Li,et al.  A comparative study on thin-walled structures with functionally graded thickness (FGT) and tapered tubes withstanding oblique impact loading , 2015 .

[34]  G. Lu,et al.  Quasi-static axial compression of thin-walled circular aluminium tubes , 2001 .

[35]  Tao Xu,et al.  A complete development process of finite element software for body-in-white structure with semi-rigid beams in .NET framework , 2012, Adv. Eng. Softw..

[36]  Guangyao Li,et al.  A high performance crashworthiness simulation system based on GPU , 2015, Adv. Eng. Softw..

[37]  Kazuhiro Saitou,et al.  Design Optimization of Vehicle Structures for Crashworthiness Using Equivalent Mechanism , 2005 .

[38]  Qing Li,et al.  On design of multi-cell thin-wall structures for crashworthiness , 2016 .

[39]  Fabian Duddeck,et al.  Multidisciplinary optimization of car bodies , 2008 .

[40]  Qing Li,et al.  On energy absorption of functionally graded tubes under transverse loading , 2016 .

[41]  Jianguang Fang,et al.  On hierarchical honeycombs under out-of-plane crushing , 2017 .

[42]  Wenjie Zuo,et al.  Cross-sectional shape design and optimization of automotive body with stamping constraints , 2016 .

[43]  Heung-Soo Kim,et al.  New extruded multi-cell aluminum profile for maximum crash energy absorption and weight efficiency , 2002 .

[44]  Jorge Ambrósio,et al.  Vehicle crashworthiness design and analysis by means of nonlinear flexible multibody dynamics , 2001 .

[45]  Jianwei Lu,et al.  Reliability-based design optimization for vehicle occupant protection system based on ensemble of metamodels , 2015 .

[46]  Jianguang Fang,et al.  Configurational optimization of multi-cell topologies for multiple oblique loads , 2018 .