Equivalent substitution criteria of aluminum for steel and its application in automobile structures

Li, Song; Bai, Jiantao; Wang, Xinchen; Song, Limin; Luo, Kai; Zuo, Wenjie

doi:10.1177/1687814020911228

Cited by 6 publications

(3 citation statements)

References 59 publications

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“…It is difficult to transform the topological structure into a manufacturable product using conventional manufacturing technologies while maintaining optimized performance. 27 For the topology optimization results, it is highly desirable that the solid cross-sections of the truss-like structures should be replaced by thinwalled cross-sections which have high inertia-to-mass ratio. 28 Figure 5 shows the topology optimization results of the UAV frame.…”

Section: Topology Optimization Designmentioning

confidence: 99%

Lightweight and maintainable rotary-wing UAV frame from configurable design to detailed design

Guo

Sun

et al. 2021

Advances in Mechanical Engineering

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Rotary-wing unmanned aerial vehicles (UAVs) are widespread in both the military and civilian applications. However, there are still some problems for the UAV design such as the long design period, high manufacturing cost, and difficulty in maintenance. Therefore, this paper proposes a novel design method to obtain a lightweight and maintainable UAV frame from configurable design to detailed design. First, configurable design is implemented to determine the initial design domain of the UAV frame. Second, topology optimization method based on inertia relief theory is used to transform the initial geometric model into the UAV frame structure. Third, process design is considered to improve the manufacturability and maintainability of the UAV frame. Finally, dynamic drop test is used to validate the crashworthiness of the UAV frame. Therefore, a lightweight UAV frame structure composed of thin-walled parts can be obtained and the design period can be greatly reduced via the proposed method.

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Section: Topology Optimization Designmentioning

confidence: 99%

Lightweight and maintainable rotary-wing UAV frame from configurable design to detailed design

Guo

Sun

et al. 2021

Advances in Mechanical Engineering

Self Cite

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“…This method simplifies the optimization process of the body section shape and facilitates the optimization design of the complex shape. Besides, Li et al 19 also proposed an equivalent substitution method of aluminum for steel to design the automobile body frame. Based on Zuo's research, Qin et al 20 improved the genetic algorithm to optimize the CSS of automobile frame structure considering the stiffness, frequency, and manufacturing constraints.…”

Section: Introductionmentioning

confidence: 99%

Multi-objective optimization of automobile body frame considering weight, rigidity, and frequency for conceptual design

Wang

Sun

Zuo

et al. 2022

Advances in Mechanical Engineering

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At the conceptual stage of product design, simplified automobile body frame constituted by thin-walled beams can effectively be used to predict global performances, including weight, rigidity, and frequency. These performances can be improved by optimizing their cross-sectional shapes (CSS) of thin-walled beams. However, it is difficult to optimize the CSS while satisfying multiple performances, because this is a multiple objectives and design variables optimization problem. The gradient-based optimization algorithms are difficult to obtain the global optimal solutions for the automobile structures. Therefore, this paper proposes an innovative multi-objective optimization method to design the CSS of automobile body by using the non-dominated sorting genetic algorithm (NSGA-II) combining with the artificial neural network. Firstly, the mechanical properties of the CSS are summarized, including open-cell, single-cell, and double-cells. These mechanical properties determine the performances of the automobile structure. Then, the multi-objective optimization model is created by using the NSGA-II while considering the weight, stiffness, and frequency, which is implemented in the self-developed CarFrame software. Finally, the proposed method is verified by optimizing the CSS for the A-pillar of automobile frame.

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“…With the continuous development of new materials such as high-strength steel, aluminum-magnesium alloy, and carbon fiber reinforced polymers (CFRP), the research of hybrid material automobiles has begun to receive more and more attention [ 7 , 8 , 9 , 10 ]. Compared with aluminum alloy and steel, CFRP can effectively reduce weight by 25–30% and 40–60%, its strength and stiffness are 5–7 times that of steel, and it has better corrosion resistance, fatigue resistance, and impact resistance [ 11 , 12 ].…”

Section: Introductionmentioning

confidence: 99%

Application Research on the Lightweight Design and Optimization of Carbon Fiber Reinforced Polymers (CFRP) Floor for Automobile

Zhang

Song

et al. 2022

Polymers

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In order to improve the lightweight level of the automotive floor, reduce material application cost, and improve integrated process manufacturing performance through structural design and optimization, this article proposes a design method to link conceptual design and detailed design and optimize the composite floor by combining free size optimization and size optimization methods. The basic theory of composite mechanics is expounded from the stress-strain theory of single-layer plates, and the stiffness and strength theory of laminated plates, which provides theoretical support for the structural design, material design, and allowable value design of composites. The mechanical properties of CFRP were tested to obtain the basic material parameters of CFRP T300/5208. With the material parameters, the CFRP floor super layers are established in Optistruct software. The shape of the floor super layers is optimized by using the free size optimization method, with the body-in-white (BIW) lightweight coefficient as the objective and the BIW performance as the constraints. The BIW lightweight coefficient is reduced from 4.35 to 4.20 after free size optimization, and the layer blocks shape is obtained and clipped based on engineering application. With the floor mass as the objective and the BIW performance as the constraints, the size optimization of the floor layer blocks thickness is optimized. Then the number of floor layers is obtained, and the CFRP floor is established in Fibersim software. Use the simulation analysis method to compare and verify the performance of the floor before and after optimization. The results show that the failure index of the floor is far less than the failure standard, while the mass of the CFRP floor is reduced by 6.8 kg compared with the original steel floor, which an improvement rate reaching 27.5%. The design and optimization methods presented in this article provide a reference for the design and application of the CFRP floor.

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Equivalent substitution criteria of aluminum for steel and its application in automobile structures

Cited by 6 publications

References 59 publications

Lightweight and maintainable rotary-wing UAV frame from configurable design to detailed design

Lightweight and maintainable rotary-wing UAV frame from configurable design to detailed design

Multi-objective optimization of automobile body frame considering weight, rigidity, and frequency for conceptual design

Application Research on the Lightweight Design and Optimization of Carbon Fiber Reinforced Polymers (CFRP) Floor for Automobile

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