Optimal crashworthiness design of a spot-welded thin-walled hat section

• Published in: Finite elements in analysis and design Vol. 42; no. 10; pp. 846 - 855
• Main Authors: Xiang, Yujiang, Wang, Qian, Fan, Zijie, Fang, Hongbing
• Format: Journal Article
• Language: English
• Published: Amsterdam Elsevier B.V 01.06.2006; Elsevier
• Subjects: Computational techniques; Crashworthiness; Exact sciences and technology; Finite-element and galerkin methods; Fundamental areas of phenomenology (including applications); Hat sections; Inelasticity (thermoplasticity, viscoplasticity...); Mathematical methods in physics; Optimization; Physics; Response surface Methodology; Solid mechanics; Spot-weld; Structural and continuum mechanics; Thin-walled; Hat sections; Spot-weld; Thin-walled; Response surface Methodology; Crashworthiness; Optimization; Axial force; Modeling; Geometrical model; Optimal design; Finite element method; Energy dissipation; Response surface; Axial load; Safety; Thin wall; Folding; Geometrical shape; Spacing; Experimental study; Enumeration(counting); Spot weld; Design process; Added mass; Automobile industry; Mixed problem; Thin walled beam; Energy absorption; Crush
• DOI: 10.1016/j.finel.2006.01.001
• ISSN: 0168-874X

In automotive industry, crashworthiness design is of special interest to ensure passengers safety and reduce vehicle costs. Thin-walled beams are the main energy absorbing structures in frontal and real collisions; therefore, it is important to investigate their energy-absorption and optimize their performance. For crashworthiness designs of thin-walled sections, much attention has been given to the size and shape designs of the cross-section, while limited study has been performed to incorporate spot-weld modelling and their numbers as design parameters in crashworthiness optimization. The spacing of spot-welds has a strong effect on crashworthiness performance, because it can change a single complete folding length. This study focuses on the optimal crashworthiness design of a spot-welded thin-walled hat section subject to an axial crushing force. Based on comparisons to experimental data, an appropriate spot-weld model is selected and used in numerical simulations. The mass of the beam is optimized subjected to constraints of required mean crushing force and bending stiffness. A “Two-step RSM-Enumeration” algorithm is employed to efficiently solve this optimization problem of mixed-type variables.