Finding three-dimensional layouts for crashworthiness load cases using the graph and heuristic based topology optimizati
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RESEARCH PAPER
Finding three-dimensional layouts for crashworthiness load cases using the graph and heuristic based topology optimization F. Beyer1
· D. Schneider1 · A. Schumacher1
Received: 26 February 2020 / Revised: 14 October 2020 / Accepted: 23 October 2020 © The Author(s) 2020
Abstract In this paper we present a new procedure using the graph and heuristic based topology optimization in order to find layouts for three-dimensional frame structures under crash loads. A three-dimensional graph describes the geometry and is used to derive a finite element shell model. The model of the frame structure consists of different profiles with continuous cross-sections. The ends of the profiles are currently rigidly connected. Each cross-section is defined by an individual twodimensional graph. After performing a simulation its results are used by competing heuristics to propose new topologies for the frame structure. Most of these heuristics are derived from expert knowledge. Over several iterations, the goal is to improve the structures mechanical behavior. Typical objectives are the minimization of the structural intrusion in a crash scenario or the minimization of the maximal contact force between structural components. The presented method includes topology optimization by heuristics and shape optimization respectively sizing by mathematical optimization algorithms. The new flexible syntax for three- and two-dimensional graphs, the optimization process and the currently used heuristics are described. The performance is demonstrated for two examples, each optimized twice with opposing objectives. Keywords Crashworthiness · Heuristic algorithms · Topology optimization · Frame structures
1 Introduction Crashworthiness requirements play an important role in the process of vehicle development. Residual spaces have to be preserved in a crash accident, while limiting acceleration peaks to avoid injuries. This results in the need for stiff structures on the one hand and energy absorbing structures on the other hand. Most of the kinetic energy is absorbed by deformation of metal structures. In addition, there are further requirements regarding structural fatigue or noise, vibration and harshness (NVH). Furthermore, the mass of the vehicle should be decreased to increase the range and efficiency of the car while leaving more light weight capacity. This paper focuses on the crashworthiness design process in the early concept phase. Numerical simulations based on the explicit finite element methods Responsible Editor: Yoojeong Noh F. Beyer
[email protected] 1
Chair for Optimization of Mechanical Structures, University of Wuppertal, Gaußstraße 20, 42119 Wuppertal, Germany
help to evaluate the above goals in the developing process. For layout finding, density-based topology optimization methods are often integrated in the design processes, since they can handle a vast amount of design variables through evaluating gradient information coming directly from the simulation (Bendsøe and Kikuchi 1988). For various reason
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