Structural optimization of automotive chassis: theory, set up, - - PowerPoint PPT Presentation

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Structural optimization of automotive chassis: theory, set up, - - PowerPoint PPT Presentation

Nov 03, 2022 693 likes •1.27k views

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions Structural optimization of automotive chassis: theory, set up, design M. Cavazzuti L. Splendi L. DAgostino E.

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SLIDE 1

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Structural optimization of automotive chassis: theory, set up, design

  • M. Cavazzuti
  • L. Splendi
  • L. D’Agostino
  • E. Torricelli
  • D. Costi
  • A. Baldini

MilleChili Lab, Universit` a di Modena e Reggio Emilia, Modena, Italy

PICOF 2012 6th International Conference Probl` emes Inverses, Contrˆ

  • le et Optimisation de Formes

Ecole Polytechnique, Palaiseau, France, April 2nd-4th

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 2

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Outline

1

Introduction

2

Structural optimization

3

Application examples

4

Automotive hood

5

Rear bench

6

Automotive chassis

7

Conclusions

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-3
SLIDE 3

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Outline

1

Introduction

2

Structural optimization

3

Application examples

4

Automotive hood

5

Rear bench

6

Automotive chassis

7

Conclusions

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 4

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

MilleChili Lab and aim of the research

MilleChili Lab

MilleChili Lab was born in february 2009 from a collaboration between Ferrari SpA and the Universit` a degli Studi di Modena e Reggio Emilia

Objectives of the laboratory

Design a novel automotive chassis in view of weight reduction and in fulfilment of given structural performance constraints according to Ferrari standards Offer a consulting service supporting Ferrari designers in the field of structural optimization of automotive components

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 5

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

MilleChili Lab rationale and main tools

A different approach to design

company know-how and designer experience systematic design by means

  • f optimization techniques

Structural optimization techniques

Topology Topometry Topography Size Shape

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 6

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Outline

1

Introduction

2

Structural optimization

3

Application examples

4

Automotive hood

5

Rear bench

6

Automotive chassis

7

Conclusions

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 7

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

What is structural optimization?

Optimization minimize

  • x∈D

f ( x) subject to c ( x) ≥ variables

  • x

experiment

  • r simulation
  • bjective

y = f ( x) constraints

  • c (

x) ≥

  • ptimization

algorithm Structural optimization variables (design space) FE domain (1 variable per element) experiment or simulation finite elements analysis

  • bjective

mass minimization constraints stiffness, displacements, modal, . . .

  • ptimization algorithm

gradient based (CONLIN or MMA)

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 8

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

What is structural optimization?

Optimization minimize

  • x∈D

f ( x) subject to c ( x) ≥ variables

  • x

experiment

  • r simulation
  • bjective

y = f ( x) constraints

  • c (

x) ≥

  • ptimization

algorithm Structural optimization variables (design space) FE domain (1 variable per element) experiment or simulation finite elements analysis

  • bjective

mass minimization constraints stiffness, displacements, modal, . . .

  • ptimization algorithm

gradient based (CONLIN or MMA)

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-9
SLIDE 9

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

What is structural optimization?

Optimization minimize

  • x∈D

f ( x) subject to c ( x) ≥ variables

  • x

experiment

  • r simulation
  • bjective

y = f ( x) constraints

  • c (

x) ≥

  • ptimization

algorithm Structural optimization variables (design space) FE domain (1 variable per element) experiment or simulation finite elements analysis

  • bjective

mass minimization constraints stiffness, displacements, modal, . . .

  • ptimization algorithm

gradient based (CONLIN or MMA)

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-10
SLIDE 10

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

What is structural optimization?

Optimization minimize

  • x∈D

f ( x) subject to c ( x) ≥ variables

  • x

experiment

  • r simulation
  • bjective

y = f ( x) constraints

  • c (

x) ≥

  • ptimization

algorithm Structural optimization variables (design space) FE domain (1 variable per element) experiment or simulation finite elements analysis

  • bjective

mass minimization constraints stiffness, displacements, modal, . . .

  • ptimization algorithm

gradient based (CONLIN or MMA)

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-11
SLIDE 11

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

What is structural optimization?

Optimization minimize

  • x∈D

f ( x) subject to c ( x) ≥ variables

  • x

experiment

  • r simulation
  • bjective

y = f ( x) constraints

  • c (

x) ≥

  • ptimization

algorithm Structural optimization variables (design space) FE domain (1 variable per element) experiment or simulation finite elements analysis

  • bjective

mass minimization constraints stiffness, displacements, modal, . . .

  • ptimization algorithm

gradient based (CONLIN or MMA)

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-12
SLIDE 12

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

What is structural optimization?

Optimization minimize

  • x∈D

f ( x) subject to c ( x) ≥ variables

  • x

experiment

  • r simulation
  • bjective

y = f ( x) constraints

  • c (

x) ≥

  • ptimization

algorithm Structural optimization variables (design space) FE domain (1 variable per element) experiment or simulation finite elements analysis

  • bjective

mass minimization constraints stiffness, displacements, modal, . . .

  • ptimization algorithm

gradient based (CONLIN or MMA)

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 13

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Variables in structural optimization

  • ptimization method

variable applicability topology element density solid & (material distribution) shell elements shell elements (deformations superposition)

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 14

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Variables in structural optimization

  • ptimization method

variable applicability topology element density solid & (material distribution) shell elements topometry element thickness shell elements (thickness distribution) (deformations superposition)

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 15

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Variables in structural optimization

  • ptimization method

variable applicability topology element density solid & (material distribution) shell elements topometry element thickness shell elements (thickness distribution) topography element offset shell elements (bead patterns) (deformations superposition)

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 16

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Variables in structural optimization

  • ptimization method

variable applicability topology element density solid & (material distribution) shell elements topometry element thickness shell elements (thickness distribution) topography element offset shell elements (bead patterns) size component thickness shell elements (thickness distribution) (deformations superposition)

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 17

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Variables in structural optimization

  • ptimization method

variable applicability topology element density solid & (material distribution) shell elements topometry element thickness shell elements (thickness distribution) topography element offset shell elements (bead patterns) size component thickness shell elements (thickness distribution) shape morphing weight factors solid & (deformations superposition) shell elements

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 18

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

A quick introduction to topology optimization

Basic equations: SIMP method for topology optimization

xi ∈ (0, 1] ∀i ρi (xi) = xiρ∗ Ei (xi) = xp

i E∗

= ⇒ ρi (xi) Ei (xi) = x1−p

i

ρ∗ E∗ ∂Ei (xi) ∂xi = pxp−1E∗

Main control parameters in topology optimization

penalty factor p sensitivity filter r

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 19

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

An example: topology optimization of a bridge

p r 1.0 1.5 2.0 2.5 1.0 1.2 1.5

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 20

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

An example: topology optimization of a bridge

p r 1.0 1.5 2.0 2.5 1.0 1.2 1.5

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 21

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

An example: topology optimization of a bridge

p r 1.0 1.5 2.0 2.5 1.0 1.2 1.5

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-22
SLIDE 22

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

An example: topology optimization of a bridge

p r 1.0 1.5 2.0 2.5 1.0 1.2 1.5

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 23

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

An example: topology optimization of a bridge

p r 1.0 1.5 2.0 2.5 1.0 1.2 1.5

images obtained with the code by Sigmund, available from http://www.topopt.dtu.dk/files/top.m

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 24

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Outline

1

Introduction

2

Structural optimization

3

Application examples

4

Automotive hood

5

Rear bench

6

Automotive chassis

7

Conclusions

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 25

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Application examples

In the following slides a few application examples of structural optimizations related to the automotive chassis weight reduction will be given, in detail:

Examples and optimizations performed

Automotive hood

topology

  • topometry
  • size

Rear bench

topography + size

Automotive chassis

topology

  • topometry
  • size

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 26

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Application examples

In the following slides a few application examples of structural optimizations related to the automotive chassis weight reduction will be given, in detail:

Examples and optimizations performed

Automotive hood

topology

  • topometry
  • size

Rear bench

topography + size

Automotive chassis

topology

  • topometry
  • size

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-27
SLIDE 27

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Application examples

In the following slides a few application examples of structural optimizations related to the automotive chassis weight reduction will be given, in detail:

Examples and optimizations performed

Automotive hood

topology

  • topometry
  • size

Rear bench

topography + size

Automotive chassis

topology

  • topometry
  • size

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-28
SLIDE 28

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Outline

1

Introduction

2

Structural optimization

3

Application examples

4

Automotive hood

5

Rear bench

6

Automotive chassis

7

Conclusions

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 29

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Numerical model, constraints and target

the reference model is Ferrari F458 Italia the objective of the optimization is the hood weight reduction the goal has to be reached by modifying the inner panel and its reinforcements with no performance loss compared to the reference model the inner panel is connected to the external skin with structural glue the outer shape, the hinges and the latch are non modifiable

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 30

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Numerical model, constraints and target

the reference model is Ferrari F458 Italia the objective of the optimization is the hood weight reduction the goal has to be reached by modifying the inner panel and its reinforcements with no performance loss compared to the reference model the inner panel is connected to the external skin with structural glue the outer shape, the hinges and the latch are non modifiable

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 31

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Loadsteps

Six different loadsteps have beeen consid- ered in the FE analyses, one for each hood stiffness target bending global stiffness torsional global stifness flaps bending stiffness hinges attachment stiffness latch attachment stiffness stabilus attachment stiffness FE tests replicate experimental setups

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 32

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Loadsteps

Six different loadsteps have beeen consid- ered in the FE analyses, one for each hood stiffness target bending global stiffness torsional global stifness flaps bending stiffness hinges attachment stiffness latch attachment stiffness stabilus attachment stiffness FE tests replicate experimental setups

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-33
SLIDE 33

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Loadsteps

Six different loadsteps have beeen consid- ered in the FE analyses, one for each hood stiffness target bending global stiffness torsional global stifness flaps bending stiffness hinges attachment stiffness latch attachment stiffness stabilus attachment stiffness FE tests replicate experimental setups

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 34

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Optimization process

Topology

  • ptimization

the mass distribution proposed by topology optimization is very different from the reference substructure topometry optimization locate critical areas needing reinforcements size optimization is used for sizing reinforcements granting structural stiffness and weight reduction

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-35
SLIDE 35

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Optimization process

Topology

  • ptimization

Topometry

  • ptimization

the mass distribution proposed by topology optimization is very different from the reference substructure topometry optimization locate critical areas needing reinforcements size optimization is used for sizing reinforcements granting structural stiffness and weight reduction

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-36
SLIDE 36

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Optimization process

Topology

  • ptimization

Topometry

  • ptimization

Size

  • ptimization

the mass distribution proposed by topology optimization is very different from the reference substructure topometry optimization locate critical areas needing reinforcements size optimization is used for sizing reinforcements granting structural stiffness and weight reduction

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 37

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Results

global torsional stiffness − 0.2% global bending stiffness + 2.4% flaps bending stiffness + 1.2% hinges attachment stiffness + 1.2% latch attachment stiffness + 5.5% stabilus attachment stiffness +10.9% hood weight −12.4%

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 38

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Outline

1

Introduction

2

Structural optimization

3

Application examples

4

Automotive hood

5

Rear bench

6

Automotive chassis

7

Conclusions

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 39

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Numerical model

the rear bench is made of a thin plate of aluminum its vibration characteristics are fundamental for passengers comfort for this reason the plate is covered with patches of damping material the FE property used in this application allows a double material layer to be defined in order to account for the bonding between aluminum and damping material

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 40

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Targets and optimization process

targets first normal mode frequency FRFs peaks (related to noise) the process adopted includes concurrent plate beads pattern and damping material distribution optimizations Size

  • ptimization

Topography

  • ptimization

damping material thickness 0 ÷ 3.2 mm beads distribution on the plate

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-41
SLIDE 41

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Targets and optimization process

targets first normal mode frequency FRFs peaks (related to noise) the process adopted includes concurrent plate beads pattern and damping material distribution optimizations Size

  • ptimization

Topography

  • ptimization

damping material thickness 0 ÷ 3.2 mm beads distribution on the plate

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 42

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Variables and results

For size optimization a single variable/component is adopted for the aluminum plate thickness, while several variables/components are considered for the damping material In comparison to the reference model several optimization runs brought to weight reductions in the range 6 to 10%

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 43

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Variables and results

For size optimization a single variable/component is adopted for the aluminum plate thickness, while several variables/components are considered for the damping material In comparison to the reference model several optimization runs brought to weight reductions in the range 6 to 10%

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 44

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Outline

1

Introduction

2

Structural optimization

3

Application examples

4

Automotive hood

5

Rear bench

6

Automotive chassis

7

Conclusions

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 45

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Topology domains

wheelbase and track suspensions, seats, engine, and gearbox joints position suspensions layout passenger compartment, engine, and gearbox size and location chassis material (aluminum) Reference model

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-46
SLIDE 46

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Topology domains

wheelbase and track suspensions, seats, engine, and gearbox joints position suspensions layout passenger compartment, engine, and gearbox size and location chassis material (aluminum) Reference model Coup´ e topology domain Spider topology domain

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 47

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Optimization constraints

1

global bending and torsional stiffness of the structure

sills displacement wheel centre displacement

2

head-on crash linearization

seat, engine, A-pillar, pedal, flame shield, dashboard displacements compliance

3

modal response of the structure

first natural mode

4

local stiffness of the suspensions, engine, and gearbox joints

wheel centres displacements engine and gearbox displacements

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-48
SLIDE 48

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Optimization constraints

1

global bending and torsional stiffness of the structure

sills displacement wheel centre displacement

2

head-on crash linearization

seat, engine, A-pillar, pedal, flame shield, dashboard displacements compliance

3

modal response of the structure

first natural mode

4

local stiffness of the suspensions, engine, and gearbox joints

wheel centres displacements engine and gearbox displacements

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-49
SLIDE 49

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Optimization constraints

1

global bending and torsional stiffness of the structure

sills displacement wheel centre displacement

2

head-on crash linearization

seat, engine, A-pillar, pedal, flame shield, dashboard displacements compliance

3

modal response of the structure

first natural mode

4

local stiffness of the suspensions, engine, and gearbox joints

wheel centres displacements engine and gearbox displacements

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-50
SLIDE 50

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Optimization constraints

1

global bending and torsional stiffness of the structure

sills displacement wheel centre displacement

2

head-on crash linearization

seat, engine, A-pillar, pedal, flame shield, dashboard displacements compliance

3

modal response of the structure

first natural mode

4

local stiffness of the suspensions, engine, and gearbox joints

wheel centres displacements engine and gearbox displacements

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-51
SLIDE 51

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Optimization process

the chassis is required to be symmetric in the spanwise direction increasing complexity optimizations adding the constraints one at a time Topology

  • ptimization

Topometry

  • ptimization

Size

  • ptimization

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-52
SLIDE 52

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Optimization process

the chassis is required to be symmetric in the spanwise direction increasing complexity optimizations adding the constraints one at a time Topology

  • ptimization

Topometry

  • ptimization

Size

  • ptimization

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-53
SLIDE 53

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Results

Coup´ e chassis Spider chassis

left view top view roof isometric view left view top view

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-54
SLIDE 54

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Results

Coup´ e chassis Spider chassis

left view top view roof isometric view left view top view

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-55
SLIDE 55

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Outline

1

Introduction

2

Structural optimization

3

Application examples

4

Automotive hood

5

Rear bench

6

Automotive chassis

7

Conclusions

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
slide-56
SLIDE 56

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Conclusions

Structural optimization methods were introduced and application examples discussed showing their potential Optimization allows addressing the design process in a more automatic and unitary way Structural optimization could provide large benefits to industries by boosting their structural design capabilities Its application requires some knowledge and care, particularly in the choice

  • f the domain and the optimization constraints

Different optimization methods have different features: a combined approach adopting different techniques is recommended for a better exploitation of these features

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.
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SLIDE 57

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions

Thank you for your attention!

MilleChili Lab millechililab@unimore.it

Structural optimization of automotive chassis MilleChili Lab — PICOF’12

  • M. Cavazzuti, L. Splendi et al.