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Design Innovation Paper

Topology Optimization of an Automotive Tailor-Welded Blank Door

[+] Author and Article Information
Guangyao Li, Fengxiang Xu

State Key Laboratory of Advanced Design
and Manufacturing for Vehicle Body,
Hunan University,
Changsha 410082, China

Xiaodong Huang

State Key Laboratory of Advanced Design
and Manufacturing for Vehicle Body,
Hunan University,
Changsha 410082, China
Centre for Innovative Structures and Materials,
School of Civil, Environmental,
and Chemical Engineering,
RMIT University,
GPO Box 2476,
Melbourne 3001, Australia

Guangyong Sun

State Key Laboratory of Advanced Design
and Manufacturing for Vehicle Body,
Hunan University,
Changsha 410082, China
e-mail: sgy800@126.com

1Corresponding author.

Contributed by the Design Innovation and Devices of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received August 8, 2013; final manuscript received September 16, 2014; published online March 5, 2015. Assoc. Editor: Kazuhiro Saitou.

J. Mech. Des 137(5), 055001 (May 01, 2015) (8 pages) Paper No: MD-13-1341; doi: 10.1115/1.4028704 History: Received August 08, 2013; Revised September 16, 2014; Online March 05, 2015

Bidirectional evolutionary structural optimization (BESO) method has been successfully applied for a wide range of topology optimization problems. In this paper, the BESO method is further extended to the optimal design of an automotive tailor-welded blank (TWB) door with multiple thicknesses. Different from the traditional topology optimization for solid-void designs, topology optimization of the TWB door needs to identify the weld lines which joint sheets with different thicknesses. The finite element (FE) model of the automotive door assembly is established and verified by a series of stiffness experiments. Then, the proposed optimization procedure is applied to the optimization of the automotive TWB indoor panel for the optimal thickness layout and weld lines locations. Numerical results give guidelines for the lightweight design of TWB components to some extent.

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Figures

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Fig. 1

Process of continuous laser welding for TWB structures

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Fig. 2

Exploded view of the door assembly: (a) outer panel and its accessories; (b) inner panel

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Fig. 3

Loading and boundary conditions for automotive door stiffness: (a) vertical sag analysis; (b) upper lateral analysis; and (c) lower lateral analysis

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Fig. 4

Stiffness experimental tests of automotive door assembly: (a) vertical sag; (b) upper lateral; and (c) lower lateral

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Fig. 5

Experimental results from door stiffness analysis. (a) vertical sag; (b) upper lateral; and (c) lower lateral.

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Fig. 6

Evolution histories of the mean compliance and volume fraction (Vf) of TWB indoor panel: (a) case a; (b) case b; (c) case c; and (d) case d

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Fig. 7

BESO optimal designs for TWB indoor panel under various load cases: (a) case a; (b) case b; (c) case c; and (d) case d

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