Study on Structural Lightweight Design of Automotive Front Side Rail Based on Response Surface Method

Abstract

Nowadays, vehicle lightweight design is a main topic in automotive industry. Crashworthiness, which is the most important performance of a full vehicle, must be always satisfied in the study on body lightweight design. This paper presents research, from the point of view of safety, of structural lightweight design of the front side rail of a passenger car. The response surface method is used to create mathematical models that represent the relationship between structural sheet thicknesses and absorbed energy of the entire structure in the frontal crash simulation, and the relationship between structural sheet thicknesses and the mass of the entire structure. Then an optimization process is performed, and the structural mass and original absorbed energy are defined as objective and constraint functions, respectively. Minimum mass and structural sheet thicknesses are obtained with the satisfaction of original absorbed energy of the front side rail structure. The weight reduction of the front side rail is 26.95%.

Lightweight design of vehicle components based on strengthening effects of low‐amplitude loads below fatigue limit

“…Substitution with a new lightweight material is the most direct and simple method in achieving a vehicle lightweight design. The greatest barrier in applying these new lightweight materials is the cost 3–4 . Therefore, it is very important and necessary to investigate a new lightweight design method for vehicle components made of traditional material at a low cost.…”

“…The greatest barrier in applying these new lightweight materials is the cost. [3][4] Therefore, it is very important and necessary to investigate a new lightweight design method for vehicle components made of traditional material at a low cost.…”

Material Optimization of BIW for Minimizing Weight

“…Sungwan Jin 1) ․Dohyun Park 1) ․Gabseong Lee 1) ․Chang Won Kim 2) ․ Heui Won Yang 3) ․Dae Seung Kim 3) ․Dong-Hoon Choi …”

Computational strategy for the crash design analysis using an uncertain computational mechanical model

“…advanced models which can be either analytical models [9,28] or nowadays, principally, computational models [1,10,11,28,30,33,39]. Such models can also be used to get an optimal design of a vehicle under crash impact loads [40,52,53]. Nevertheless, such modeling is a challenge in regard to the complexities of the computational model because the geometrical and material nonlinearities must be taken into account.…”

“…In addition, the notion of derivative of r → U(r) with respect to r would make sense and consequently, the notion of the neighborhood in the set of all the possible configurations could be introduced. In such a case, an interpolation method, such as the surface response method, could be carried out (as in [40,51,53]) and it would be required that all the points r 1 ,...,r n be inside an opened ball of R with a "small enough" radius. Nevertheless, such a method cannot easily be used as soon as the one-to-one correspondence does not exist.…”