Flexible Graph Syntax for the Topology Optimization of Crashworthiness Profile Structures Made from Thermoplastic Composites

Abstract

The design process of fiber-reinforced plastics (FRP) is a challenging task, especially concerning passenger vehicles in crashworthiness applications where manufacturing limitations and requirements regarding passive safety have to be considered. Numerical optimization can be a helpful tool during the design process, but most available methods are not applicable because analytical sensitivities are not available in crash simulations. The Graph and Heuristic based Topology Optimization (GHT) can be utilized to optimize the topology of cross-sections of crashworthiness structures while fulfilling a wide range of manufacturing constraints, but it has to be extended for composites. Since the topology changes during optimization runs, the stress state changes as well. This demands high predictive capabilities on the material model. This paper presents the necessary adjustments to describe composite profile structures within the GHT method. A commercial material model for LS-Dyna is parameterized and used for the calculation process.

Finding three-dimensional layouts for crashworthiness load cases using the graph and heuristic based topology optimization

“…-Not much work is needed to interpret the optimized structures since they are based on geometries that can be exported with an interface, e.g., to a STEP-file. -The graph can be used for further structural optimization with cross-sections like filament winding profiles (Schneider et al 2019), rib layouts (Schneider and Schumacher 2018) or flange structures (Link et al 2019). 4 Derived finite element model…”