Topology, size and shape optimization of an automotive cross car beam
Topology, size and shape optimization of an automotive cross car beam
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DOI：
10.1177/0954407014561279
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发表时间：
2015-09
期刊：
影响因子：
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通讯作者：
Chao Li;I. Kim
中科院分区：
文献类型：
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作者：
Chao Li;I. Kim
汽车横梁梁支持仪表板，包括加热，通风和空调系统，膝盖安全气囊，方向盘和方向盘系统以及中央控制台。避免谐振频率和提高驾驶舒适度是横梁设计的主要性能要求。由于汽车行业中质量生产的性质，因此对制造性的考虑很重要，并且该行业的当前实践确实将有关方向盘和方向盘系统的详细信息授予了跨汽车设计师。本文的目的是通过使用轻量级材料来考虑两个实用的制造过程（挤出和铸造），并假设在现实情况下，只有在该情况下只有有限的信息来执行横梁的完整拓扑，大小和形状优化。转向柱和方向盘系统可供横梁设计器使用。首先，开发了方向盘和方向盘系统的简化有限元模型，并使用优化对其进行校准，以使简化有限元模型的重要行为与真实的方向盘和方向盘的重要行为一致系统。进行了拓扑优化，以确定连接转向柱和方向盘系统和横车梁的零件的最佳材料分布。然后，从成本和制造性的角度来解决了有利拓扑结果的几何学重新解释，以解决问题。随后进行了灵敏度研究，以确定尺寸优化设计变量，对频率性能产生重大影响。最后，一起进行尺寸和形状优化，以进一步优化横梁束结构的细节。与钢设计相比，最佳铝设计的重量减少了近40％，同时满足了重要的性能要求。
An automotive cross car beam supports instrument panels including the heating, ventilation and air-conditioning system, the knee airbags, the steering-column and steering-wheel system and the central console. Avoiding resonant frequencies and improving driving comfort are major performance requirements in the design of a cross car beam. Because of the nature of mass production in the automotive industry, the consideration of manufacturability is important, and the current practice in the industry does grant detailed information on the steering-column and steering-wheel system to the cross car beam designer. The objective of this paper is to perform a complete topology, size and shape optimization of a cross car beam by using a lightweight material, by considering two practical manufacturing processes (extrusion and casting) and by assuming a realistic situation where only limited information on the steering-column and steering-wheel system is available to the cross car beam designer. First, a simplified finite element model of the steering-column and steering-wheel system was developed, and it was calibrated using optimization such that the important behaviour of the simplified finite element model agrees with that of the real steering-column and steering-wheel system. Topology optimization was performed to determine the optimal material distribution for the parts that connect the steering-column and steering-wheel system and the cross car beam. Then a geometry reinterpretation of the favourable topology result was performed to address the concerns from the viewpoints of the cost and the manufacturability. A sensitivity study was conducted subsequently to determine the size optimization design variables with significant effects on the frequency performance. Finally, size and shape optimization were performed together to optimize further the details of the cross car beam structure. The weight of the optimal aluminium design was reduced by nearly 40% compared with the steel design while the important performance requirements are met.