Multi-Disciplinary Design Optimization of a Composite Car Door for Structural Performance, NVH, Crashworthiness, Durability and Manufacturability

Abstract

Among various efforts pursued to produce fuel efficient vehicles, light weight engineering (i.e. the use of low-density structurally-efficient materials, the application of advanced manufacturing and joining technologies and the design of highly-integrated, multi-functional components/sub-assemblies) plays a prominent role. In the present work, a multidisciplinary design optimization methodology has been presented and subsequently applied to the development of a light composite vehicle door (more specifically, to an inner door panel). The door design has been optimized with respect to its weight while meeting the requirements /constraints pertaining to the structural and NVH performances, crashworthiness, durability and manufacturability. In the optimization procedure, the number and orientation of the composite plies, the local laminate thickness and the shape of different door panel segments (each characterized by a given composite-lay-up architecture and uniform ply thicknesses) are used as design variables. The methodology developed in the present work is subsequently used to carry out weight optimization of the front door on Ford Taurus, model year 2001. The emphasis in the present work is placed on highlighting the scientific and engineering issues accompanying multidisciplinary design optimization and less on the outcome of the optimization analysis and the computational resources/architecture needed to support such activity.

Weight reduction analysis of a four-door passenger car using computer-aided modelling and experimental investigation

“…There are several approaches [1], [2], [22] through which lightweight model can be achieved such as resizing the parts, lightweight materials, optimizing the existing design, revising manufacturing processes and removing content and features. This research methodology is focused more towards material's change i.e., lightweight materials approach.…”

“…Such benefits include reduced fatigue load and improvements in manufacturing assembly. [1] As a result, there continues to be a critical push to reduce mass in vehicle body and door designs. Reducing weight by 100 kg leads to a fuel savings of 0.3 to 0.5 L/100 km and 8.5g to 14g CO2/km with gasoline engines as shown in the Fig.…”

“…1. Effect Weight Reduction on CO2 Emission and Fuel Consumption [2] Consider an adjustment of the gear shifting without a change in elasticity and acceleration values due to the lower weight [1]. A lightweight body of a vehicle can be achieved through any combination of five different approaches to lightweight design as shown in Fig.…”

Design and manufacturing front hood for electric vehicle by carbon fibber

“…Different approaches with varying design goals and realizations have been discussed in recent publications. The main goals for the use of adaptive structures can be summarized as described in [8].…”