Customer Request Background and Objective
Utilize optimization techniques to enhance their vehicle body structure to reduce weight and complexity of components.
Optimal used a multidisciplinary CAE design optimization approach by incorporating all relevant design variables simultaneously. This methodology offered the most precise optimization by addressing the effects of the interactions between the relevant variables:
The Resulting Benefits of CAE Design Optimization
Topology optimization of a stamped steel to cast aluminum conversion
Reduce weight of stamped steel vehicle component utilizing lighter weight materials and engineering optimization techniques.
Utilizing topology optimization, Optimal identified the high stress points for the component to determine design iterations that would reduce mass before considering lighter weight materials. A specific aluminum alloy was selected as a replacement for stamped steel. Further optimization of component structure was conducted to ensure component integrity based on material trade-offs including hardness, stress strain curve, thermal conductivity.
The Resulting Benefits of Lightweighting Optimization:
CAE Engineering Optimization - Crossmember
Back-of-cab crossmember was found to develop cracks during durability testing.
Results - Baseline
Maximum von Mises stress of 754 MPa was observed during FE simulation.
Stress areas above yield of the material correlated with areas where the cracks formed during durability testing.
Design Optimization - Proposal I
Topology optimization resulted in design shown.
Stress analysis resulted in a maximum von Mises stress of 633 MPa.
Design Optimization - Proposal II
New design space defined.
Stress analysis resulted in a maximum von Mises stress of 427 MPa.
Summary of Results
Background and Objective