Yongxin Men;Guojun Zheng;Huicai Zelong Lu;Zelong Wang;
Research and/or Engineering Question.slObjective:The crashworthincss and lightweight of a vehicle were directly affected by the front structure of body frame,including the front-end impact beam,side rails,crash boxes and A-pillars.The key to lightweight is how to design a body frame that could reduce weight and meet safety requirements.The design optimization method based on finite element simulation could save cost and improve efficiency.In this research,this method is applied to the safety and lightweight design of the body frame,and a parametrical design optimization method is explored in consideration of safety and lightweight,offering technical support for automotive lightweight design.Methodology:Firstly,a parametrical modelling process was implemented on the substructure of a certain car according to the parametrical simulation.Secondly,a design optimization model was established with the parameters of body frame as the design variables,lightweight as the objective,and the front crashworthiness as the constraint.Thirdly,the design optimization model was solved and the optimal design parameters were obtained.Finally,the real vehicle was built up with optimal design parameters and experimental validation was carried out for safety and lightweight.Results:The fast modelling method about parametrical finite element model of body frame was constructed in the study,taking a real car of a Chinese domestic brand as the example.The optimization of finite element design method based on crashworthiness and lightweight of body frame was achieved and this method takes the safety and lightweight into account at the same time.It serves as an effective way to improve the efficiency of vehicle lightweight.Limitations of this study:Due to the complexity of vehicle structure,the parametrical design was merely implemented on some key sizes and parts which can affect structure strength obviously,however,the crash safety and lightweight requirement could be fulfilled from the final parametrical design.What does the paper offer that is new in the field including in comparison to other work by the authors? Through this parameterization process,which was based on the substructure,the rapid modifications of actual structures and automatic linite element model development became reality.Therefore,this technique was different to the parametrical designs and simulations of the traditional CAD/CAE method.Conclusions:The fast modelling method of linite element parametrical model and its optimization in respect of safety and lightweight is feasible.It can offer technical support for automotive lightweight.
Body frame;;Parametrical design;;Crashworthiness;;Lightweight;;Design optimization
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