Analytical Sensitivity Analysis Method of Cross-Sectional Shape for Thin-Walled Automobile Frame Considering Global Perf
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ANALYTICAL SENSITIVITY ANALYSIS METHOD OF CROSSSECTIONAL SHAPE FOR THIN-WALLED AUTOMOBILE FRAME CONSIDERING GLOBAL PERFORMANCES Yanhua Ma, Xinchen Wang and Wenjie Zuo* School of Mechanical and Aerospace Engineering, Jilin University, Changchun 130025, China (Received 26 August 2019; Revised 23 December 2019; Accepted 24 December 2019) ABSTRACTAt the conceptual design stage, thin-walled beams (TWBs) with the complex cross-sectional shapes are extensively used to compose the automobile frame. Thus, the performances of automobile frame are determined by crosssectional shapes of TWBs. Currently, the modifications of complex cross-sectional shapes depend on the experience of engineers, which often causes the design risk. Meanwhile, to our knowledge, the previous studies mainly focused on the regular cross sections and paid little attention for the complex cross-sectional shape for the automobile frame. Therefore, this paper proposes an analytical sensitivity analysis method to modify the complex cross-sectional shapes. This method regards the coordinates of points and the thicknesses of sheets as design variables to describe the cross-sectional shapes. The bending stiffness, torsional stiffness and frequency are used to evaluate the performances of automobile frame. Finally, an example of the RAV4 automobile frame verifies that the analytical sensitivity analysis method can effectively guide the modification of the cross-sectional shape and achieve the lightweight automobile frame. KEY WORDS : Automobile design, Automobile frame, Thin-walled beams, Cross-sectional shape, Sensitivity analysis
1. INTRODUCTION
cylindrical cross section. Besides, genetic algorithm was adopted to solve the optimization of cross-sectional shape for beam which was subjected to various loading conditions (Griffiths and Miles, 2003). Furthermore, the body beam-like sections were used to effectively and accurately optimize the low frequency of automobile frame by using finite element model (FEM) (Donders et al., 2009). Shin et al. (2018) used the cross-sectional shape to accurately depict the complicated deformations that occurred in composite thin-walled box beams. In practice, TWBs with multiple-cell cross sections were extensively applied in automobile frame. Hence, Apostol et al. (2002) presented a general approach for detailed analysis and design modification of cross section. Also, the constraints, such as complex loads, material and geometrical characteristics, were considered into minimizing the cross-sectional area of TWBs (Anđelić, 2003). For more complicated beam structures and automobile frame, Yoshimura et al. (2005) proposed crosssectional shape generation methods for thin-walled automobile frame designs, but only the open-cell, singlecell and double-cell sections were applied in the automobile frame. The optimization of cross-sectional shape for joined structural frames and finite element analysis were used to evaluate the stiffness of automobile frame (Lyu et al., 2006; Re
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