Title: Shape and sizing optimisation of automotive structures with deterministic and probabilistic design constraints

Authors: Masoud Rais-Rohani, Kiran N. Solanki, Erdem Acar, Christopher D. Eamon

Addresses: Center for Advanced Vehicular Systems, Department of Aerospace Engineering, Mississippi State University, Mississippi State, MS 39762, USA. ' Center for Advanced Vehicular Systems, Mississippi State University, Mississippi State, MS 39762, USA. ' Department of Mechanical Engineering, TOBB University of Economics and Technology, Sogutozu, Ankara 06560, Turkey. ' Department of Civil and Environmental Engineering, Wayne State University, Detriot, MI 48202, USA

Abstract: This paper presents the results of a study on the combined shape and sizing optimisation of automotive structures while examining the effects of different design constraints and associated uncertainties on reliability and efficiency of the optimum designs. Nonlinear transient dynamic finite element analysis is used for full- and offset-frontal crash simulations of a full vehicle model. Surrogate models are developed for the intrusion distance and peak acceleration responses at different vehicle locations based on the material and geometric characteristics of the rail component. The obtained solutions provide insight on the effect of uncertainties in optimum design of automotive structures.

Keywords: RBDO; reliability-based design optimisation; automotive crashworthiness; metamodelling; structural reliability; mesh morphing; shape optimisation; sizing optimisation; crash simulation; automotive structural design; probabilistic design; vehicle design; automobile industry; design constraints; simulation; finite element analysis; FEA; intrusion distance; peak acceleration.

DOI: 10.1504/IJVD.2010.036839

International Journal of Vehicle Design, 2010 Vol.54 No.4, pp.309 - 338

Accepted: 11 Feb 2010
Published online: 12 Nov 2010 *

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