Shape Optimization for Thin Sheet Structures Under Crash Loads
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Solution Overview
Problem
Current methods for shape optimization of structural bodies, particularly in the automotive industry, face challenges in applying optimization techniques to parts receiving external forces like collision forces, and struggle to reflect optimized shapes in thin sheet structures effectively.
Innovation Solution
A method and apparatus that use a computer to optimize structural body models by setting a design space, generating an optimization block model with three-dimensional elements, connecting it to the structural body, setting material properties, and performing crashworthiness and stiffness analyses to determine an optimum shape for improved crashworthiness and stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If topology optimization is applied to thin sheet structures, then weight reduction is achieved, but the design space cannot be properly set and load reflection is difficult
Solution Approach 1:
A three-dimensional element model is introduced as an intermediary between the thin sheet structure and the optimization algorithm. This model serves as a mediator that can properly receive loads and reflect structural behavior, enabling topology optimization to be applied to thin sheet structures without directly constraining the original thin sheet elements.
Solution Approach 2:
Instead of directly optimizing the thin sheet structure, a three-dimensional element model copying the design space is created. This copied model allows proper load application and constraint setting, while the optimization results are then transferred back to the original thin sheet structure.
2Force
If three-dimensional elements are used for optimization, then load reflection is improved, but the optimized shape is difficult to reflect in thin sheet structures
Solution Approach 1:
The optimization process incorporates feedback mechanisms where the three-dimensional element model analysis results are used to guide the shape optimization of the thin sheet structure. The load reflection capabilities of the three-dimensional model provide feedback that ensures the optimized shape can be properly reflected in the original thin sheet structure.
Solution Approach 2:
The solution transitions from two-dimensional thin sheet elements to three-dimensional elements for the optimization model. This dimensional change enables proper load reflection and constraint application, while the optimized shape is then projected back to the two-dimensional thin sheet structure through appropriate mapping techniques.
3Device complexity
If mathematical operations are used for optimization, then computation is simplified, but the method cannot solve problems of structural bodies receiving external forces
Solution Approach 1:
The three-dimensional element model acts as an intermediary that bridges simplified mathematical operations and complex external force handling. It allows the use of relatively simple optimization algorithms while maintaining the capability to accurately model and respond to external forces such as collision loads.
Solution Approach 2:
The structural body is segmented into a thin sheet structure and a separate three-dimensional element optimization model. This segmentation allows the complex external force handling to be isolated in the three-dimensional model, while the optimization computation can be performed more simply on this separated model.
Data Source
AI summary
A method for analysis of shape optimization includes: a design space setting step of setting a design space; an optimization block model generating step of generating an optimization block mode in the set design space; a connection processing step of connecting the generated optimization block model with a structural body model; a material property setting step of setting a material property for the optimization block model; a crashworthy optimum shaping condition setting step of setting a crashworthy optimum shaping condition for the optimization block model; a crashworthiness analysis condition setting step of setting a crashworthiness analysis condition for the structural body model; a three-dimensional element necessity calculation step of executing a crashworthiness analysis on the optimization block model, and calculating information related to necessity of each of three-dimensional elements of the optimization block model; and an optimum shape determining step of determining an optimum shape.