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TECHNICAL BRIEFS

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

[+] Author and Article Information
Y. Zhang, P. Zhu, G. L. Chen, Z. Q. Lin

School of Mechanical Engineering, Shanghai Jiao Tong University, 800 Dongchuan Road, Min Hang, Shanghai 200240, China

J. Mech. Des 129(5), 553-557 (Jun 09, 2006) (5 pages) doi:10.1115/1.2712223 History: Received December 14, 2005; Revised June 09, 2006

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%.

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Copyright © 2007 by American Society of Mechanical Engineers
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Figures

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Figure 1

Comparison of deformed shape of full vehicle: t=0ms, t=30ms, t=60ms, and t=90ms

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Figure 2

Acceleration of a key point in A-pillar

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Figure 3

Deformed shape of the front side rail

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Figure 4

Front side rail structure: (a) original structure (thickness 1.5mm) and (b) modified structure

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Figure 5

Equiradial design with octagon

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Figure 6

Deformed shape of the front side rail: (a) original structure and (b) lightweight structure

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Figure 7

Absorbed energy of front side rail

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Figure 8

Absorbed energy of full vehicle

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Figure 9

Force response of full vehicle

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Figure 10

Acceleration of a key point in A-pillar

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