Crashworthiness optimization of crash box with 3D-printed lattice structures

Hou, Wenbin; He, Ping; Yang, Yi; Sang, Lin

doi:10.1016/j.ijmecsci.2023.108198

Cited by 45 publications

(15 citation statements)

References 61 publications

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“…Zhou et al 37 carried out multi-objective design optimization of a novel NPR crash box based on optimal Latin square design method, RSM and NSGA-II. Hou et al 50 carried out a multi-objective optimization of a novel crash box composed of Al shell and 3D-printed lattice core for maximum specific energy absorption (SEA) and minimum mass using optimal Latin hypercube sampling (OLHS), RSM and NSGA-II. Tan et al 36 conducted a multi-objective optimization of a novel auxetic hierarchical honeycomb crash box by combining RSM with NSGA-II and archive-based micro genetic algorithm (AMGA).…”

Section: Introductionmentioning

confidence: 99%

Multi-objective robust optimization of foam-filled double-hexagonal crash box using Taguchi-grey relational analysis

Xiong,

Wang,

Wang

et al. 2023

Advances in Mechanical Engineering

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In this paper, a novel thin-walled double-hexagonal crash box is first proposed and then multi-objective robust optimized for better overall crashworthiness under multi-angle impact loading, using a proposed hybrid method combining aluminum foam-filling and Taguchi-grey relational analysis (GRA). Specifically, the finite element (FE) models of the regularly-shaped double-hexagonal column (DHC) extracted from original irregularly-shaped crash box under multi-angle impact loading, including hollow (H-DHC) and foam-filled (F-DHC), are first built and validated by experiments. On this basis, a comprehensive crashworthiness comparison is conducted to explore relative merits of F-DHC over original H-DHC under multi-angle impact loading. After that, the F-DHC is multi-objective robust optimized for maximizing overall specific energy absorption (SEAθ) and minimizing overall initial peak crushing force (IPCF0) simultaneously under multi-angle impact loading, using a hybrid method of Taguchi-GRA. At last, a bumper-crash box integrated crashworthiness analysis under multi-angle impact loading is executed to further verify the optimization. The optimal F-DHC and the optimized crash box within the optimal F-DHC demonstrate evident improvement of crashworthiness compared to their respective initial designs, indicating aluminum foam-filling combined with Taguchi-GRA could be an effective approach for multi-objective robust optimization of the novel crash box and other similar vehicle structures.

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Section: Introductionmentioning

confidence: 99%

Multi-objective robust optimization of foam-filled double-hexagonal crash box using Taguchi-grey relational analysis

Xiong,

Wang,

Wang

et al. 2023

Advances in Mechanical Engineering

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“…[38,39] Nonstochastic cellular solids are interconnected tessellations of optimized complex geometries unit cells capable of sustaining considerable deformations at low weight penalty. [40,41] Lattice structures have been printed with a broad range of engineering materials using various additive manufacturing techniques, including fused filament fabrication, [42,43] material jetting, [40,44] vat photopolymerization, [22] and selective laser sintering. [45][46][47] These additively manufactured ordered lattice structures strategically (i.e., through intentional design and formal optimization) fill several gaps in property maps, [48][49][50] including stiffness, [51,52] strength, [53] specific energy absorption (SEA), [54] and toughness.…”

Section: Introductionmentioning

confidence: 99%

Structural Performance of Additively Manufactured Composite Lattice Structures: Strain Rate, Cell Geometry, and Weight Ratio Effects

Singh,

Ngo,

Huynh

et al. 2023

Adv Eng Mater

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The proliferation of ordered cellular structures in industrial and technological applications is justified by their superior mechanical performance, including tunable energy absorption strategies and potential multifunctionality. This research evaluates the mechanical response of composite lattice structures fabricated using vat photopolymerization additive manufacturing process and printable particulate composite materials. Several generations of modified printable resins are prepared by hybridizing flexible resin with varying glass microballoons reinforcement weight percentages. Multifaceted characterization regiments highlight the process–property–performance interrelationship by submitting printed composite structures to quasi‐static and impact‐loading scenarios combined with digital stills and high‐speed photography, respectively. Image analyses of optical and scanning electron micrographs quantify the dimensional accuracy of the composite lattice structures with cylindrical and hexagonal cellular geometries. The mechanical characterization uncovers the effect of cell geometry and reinforcement on the global structural behavior, eliciting differences in load‐bearing capacity, local strain developments, and structural densification. Exploratory digital image correlation supports the global structural deformations, revealing their relationship with the developed local strain state within the unit cells. The outcomes of this research elucidate the effect of strain rate, unit cell geometry, and reinforcing ratios on the structural performance of composite lattice structures at the macro‐ and microstructure levels.

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“…7 Given the advantages mentioned above and the possibility of creating complex geometries through AM, designing interior structures for 3D printing opens doors to new opportunities for improved product manufacturing and applications. [8][9][10] Some fields of study are energy storage as batteries, 11 sensors, 12 in the automobile industry as crash boxes 13 or sandwich panels, 14 and the aeronautical industry as compressor impellers. 15 Intricate anatomies fabricated by AM are widely studied for medical purposes, 10,16 especially to replicate the mechanical properties of bones and reduce the weight of implants.…”

Section: Introductionmentioning

confidence: 99%

Additive manufacturing of non-uniform scaffolds for mass center control

Robles-Lorite,

Dorado-Vicente,

Medina-Sánchez

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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In addition to solid components, additive manufacturing can shape parts with internal structures or lattices to control specific mechanical properties such as the relation between strength and mass, inertia, and the center of mass. This study shows a strategy to produce scaffolds based on linear mapping, exponential parameterization, and Voronoi's diagram. The approach provides layer by layer, a net of lines denser on a specific layer point that can be defined to control the layer center of mass. This method is compatible with current CAD software and three-dimensional printing procedure stages; thus, it is easily reproducible. Furthermore, different linear mapping rulings and parameterizations were tested to evaluate the method's capabilities for modifying the center of mass of a symmetrical NACA 0015 profile. The numerical and experimental results show that it is possible to accommodate the center of mass between −8 and 18 mm to the NACA's theoretical center of mass.

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Crashworthiness optimization of crash box with 3D-printed lattice structures

Cited by 45 publications

References 61 publications

Multi-objective robust optimization of foam-filled double-hexagonal crash box using Taguchi-grey relational analysis

Multi-objective robust optimization of foam-filled double-hexagonal crash box using Taguchi-grey relational analysis

Structural Performance of Additively Manufactured Composite Lattice Structures: Strain Rate, Cell Geometry, and Weight Ratio Effects

Additive manufacturing of non-uniform scaffolds for mass center control

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