Effects of roof crush loading scenario upon body in white using topology optimisation

Christensen, Jesper; Bastien, Christophe; Blundell, Mike

doi:10.1080/13588265.2011.625640

Cited by 22 publications

(7 citation statements)

References 15 publications

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“…Creating loadcases representative of the crash scenarios and the maximum crash pulse obtained from the FE (crashworthiness) analyses of section 2, the topology optimisation could be completed. This utilised an isotropic material model and the Inertia Relief (IR) boundary conditions [7], [8], [9], [10] and [11] it was possible to extract suggestions for idealised loadpaths of the future Microcab vehicle as illustrated in Figure 25. From the optimisation results, Figure 25, it may be suggested that the front-end of the current Microcab concept design does not require any significant modifications.…”

Section: Future Topologymentioning

confidence: 99%

Lightweighting of a hydrogen fuel cell vehicle whilst meeting urban accident criteria

Grimes

Bastien

Christensen

et al. 2013

2013 World Electric Vehicle Symposium and Exhibition (EVS27)

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The aim of this paper is to assess the safety performance of a lightweight hydrogen fuel cell city concept vehicle entitled Microcab [1]. The Microcab is a lightweight 4 seat hydrogen fuel cell concept vehicle with a combined mass (excluding passengers) of less than 800kg. The Microcab has a range of 180 miles; it includes a hydrogen fuel tank pressurised to 350 bar. The research focuses on urban accident scenarios; including frontal, lateral and compatibility loadcases. All loadcases utilise urban speeds, i.e. speeds ranging up to 40km/h for frontal impacts. The crashworthiness of the Microcab has been analysed using explicit non-linear Finite Element Analysis (FEA). The study concludes that within the limitations of the material parameter definitions and mass distributions; the crashworthiness in connection with urban accident scenarios is good. This includes aspects such as vehicle compatibility loadcases and protection of the hydrogen fuel tank e.g. for intrusion. The outcome of the study also suggests structural refinements for the future Microcab final production model; with an aim of further improving the vehicles' crashworthiness. These refinements include raising the primary front crash structure to better align it with that of a Sports Utility Vehicle (SUV) as well as bracing the fuel cell area in case of a rear impact in order to better protect this vital component. It is also suggested that adhesive joints were suitable for structural crash integrity in all the loadcases studied within this paper, including low speed impact for repairability. A structural optimisation study has also been undertaken utilising Design Of Experiments (DOE), shapesize-and topology optimisation. DOE was employed to further improve the stiffness of the chassis with respect to safety, whilst minimising the mass increase. Topology optimisation models based on the maximum crash force magnitudes computed in the initial part of the study were also setup; the results of these suggested future changes to the Microcabs' floor layout could be utilised to further enhance the vehicles crashworthiness.

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Section: Future Topologymentioning

confidence: 99%

Lightweighting of a hydrogen fuel cell vehicle whilst meeting urban accident criteria

Grimes

Bastien

Christensen

et al. 2013

2013 World Electric Vehicle Symposium and Exhibition (EVS27)

Self Cite

View full text Add to dashboard Cite

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“…On the other hand, there are some prerequisites to fulfill that are directly related to mechanical properties and safety standards. The crashworthy design of a vehicle structure has become the crucial task for decades in the automotive industry (Ambrosio 2001;Duddeck et al 2016;Jones and Wierzbicki 1983;Christensen and Bastien 2015;Christensen et al 2012).…”

Section: Introductionmentioning

confidence: 99%

Crashworthiness optimization of front rail structure using macro element method and evolutionary algorithm

Pyrz

Krzywoblocki

2019

Struct Multidisc Optim

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In this paper, the research on crashworthiness optimization of thin-walled structures is presented. The model of "S"-shaped frame subjected to complex crush load is analyzed. The objective of the study is to determine the optimal dimensions of the space frame cross section so as to achieve the maximal energy absorption of the structure and to fulfill the design requirements related to the crushing force value and the geometry relationship. The Visual Crash Studio (VCS) software, based on the macro element methodology, is used to simulate the response of a thin-walled beam during the impact and to determine crashworthy parameters. The results present a very good correlation with the finite element calculations but can be obtained in a much shorter time. The VCS software was coupled to evolutionary algorithm developed to determine the best solution. The optimization procedures revealed the necessity of a new design criterion related to maximal bending moments in the structure. This formulation enabled to obtain very good results after short processing on a PC computer. The proposed approach may be successfully used at early stages of the crashworthiness analysis.

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“…In particular, rollover crashes are serious safety problems for light-weight vehicles [6]. For this reason, many studies have been conducted on the optimization of roof strength in regard to a simulated vehicle rollover [7][8][9]. Accidents, including vehicle rollovers, have high nonlinearity and it is difficult to predict the deformation behavior of parts over time after an accident.…”

Section: Introductionmentioning

confidence: 99%

Roof-Crush Protection Design of Automotive Bodies Using Clustering and Pattern Recognition

et al. 2019

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Computer-aided engineering (CAE) tools play an indispensable role in the vehicle development process. However, it is difficult to accurately predict the relationships and behavior of automotive bodies in vehicle crashes owing to high-order nonlinearity and numerous design variables of the automotive body structure. In this study, clustering and pattern recognition techniques were used to develop a novel optimization design of an automotive body considering roof crushing by vehicle rollover. The large-scale data were clustered to find the strong and weak clusters, and new response surface models were acquired by clustering analysis to achieve better performance than the response surface model of traditional optimization. For an efficient robust design, clusters with weak performance were excluded from the optimum solution. Finally, it was confirmed that the solutions by the proposed optimization technique were better than those obtained by the traditional optimum method based on a comparative analysis by various cluster combinations.

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Effects of roof crush loading scenario upon body in white using topology optimisation

Cited by 22 publications

References 15 publications

Lightweighting of a hydrogen fuel cell vehicle whilst meeting urban accident criteria

Lightweighting of a hydrogen fuel cell vehicle whilst meeting urban accident criteria

Crashworthiness optimization of front rail structure using macro element method and evolutionary algorithm

Roof-Crush Protection Design of Automotive Bodies Using Clustering and Pattern Recognition

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