A light?weight design method of integrated structural topology and size co?optimization for the force?performance?structure of complex structural parts is presented in this paper. Firstly, the supporting function of a...A light?weight design method of integrated structural topology and size co?optimization for the force?performance?structure of complex structural parts is presented in this paper. Firstly, the supporting function of a complex structural part is built to map the force transmission, where the force exerted areas and constraints are considered as connecting structure and the structural configuration, to determine the part performance as well as the force routines. Then the connecting structure design model, aiming to optimize the static and dynamic performances on connection configuration, is developed, and the optimum design of the characteristic parameters is carried out by means of the collaborative optimization method, namely, the integrated structural topology optimization and size optimization. In this design model, the objective is to maximize the connecting stiffness. Based on the relationship between the force and the structural configuration of a part, the optimal force transmission routine that can meet the performance requirements is obtained using the structural topology optimization technology. Accordingly, the light?weight design of conceptual configuration for complex parts under multi?objective and multi?condition can be realized. Finally, based on the proposed collaborative optimization design method, the optimal performance and optimal structure of the complex parts with light weight are realized, and the reasonable structural unit configuration and size charac?teristic parameters are obtained. A bed structure of gantry?type machining center is designed by using the proposed light?weight structure design method in this paper, as an illustrative example. The bed after the design optimization is lighter 8% than original one, and the rail deformation is reduced by 5%. Moreover, the lightweight design of the bed is achieved with enhanced performance to show the effectiveness of the proposed method.展开更多
The size effects of microstructure of lattice materials on structural analysis and minimum weight design are studied with extented multiscale finite element method（EMsFEM） in the paper. With the same volume of base ...The size effects of microstructure of lattice materials on structural analysis and minimum weight design are studied with extented multiscale finite element method（EMsFEM） in the paper. With the same volume of base material and configuration, the structural displacement and maximum axial stress of micro-rod of lattice structures with different sizes of microstructure are analyzed and compared.It is pointed out that different from the traditional mathematical homogenization method, EMsFEM is suitable for analyzing the structures which is constituted with lattice materials and composed of quantities of finite-sized micro-rods.The minimum weight design of structures composed of lattice material is studied with downscaling calculation of EMsFEM under stress constraints of micro-rods. The optimal design results show that the weight of the structure increases with the decrease of the size of basic sub-unit cells. The paper presents a new approach for analysis and optimization of lattice materials in complex engineering constructions.展开更多
The woven textile sandwich composite（WTSC） is a promising lightweight composite.In bending,two competing core shearing failure modes reduce the strength;deflection induced by the core shearing deformation reduces th...The woven textile sandwich composite（WTSC） is a promising lightweight composite.In bending,two competing core shearing failure modes reduce the strength;deflection induced by the core shearing deformation reduces the flexural rigidity.To replace a solid composite laminate,the span of WTSC panel must be greater than a critical value,which was deduced on the condition that the load capacity and flexural rigidity of the WTSC panel are equal to those of the composite laminate.Three WTSC panels were tested in bending,so that the failure modes were observed,and the critical spans were determined.Using the alternative design method,the WTSC based wind deflector with reduced weight has been fabricated and mounted on the CRH（China Railway High-speed）.展开更多
This paper focuses on an estimation of light weighting opportunities for the frame structure of com- mercial road vehicles. This estimation is based on simpli- fied static load cases which play a predominant role for ...This paper focuses on an estimation of light weighting opportunities for the frame structure of com- mercial road vehicles. This estimation is based on simpli- fied static load cases which play a predominant role for the dimensioning of a frame structure and therefore these simplifications are not putting the general validity of the conclusions into question. A comparison of different ma- terials under this scenario shows that light metals do not show any weight reduction advantage in comparison to steel while a material-independent topology optimization has more weight reduction potential for the frame structure than a simple change of materials. Considering the con- straints of part complexity which is directly linked with production and assembly cost, the ladder frame structure has become the current state of the art design. Thus the paper also puts a spotlight on basic rules of node design and vertical load induction in order to keep the weight of such a design as low as possible. Practical examples from manufacturers show that the weight of a commercial vehicle could be reduced by 10%, and main parts of the frame structure could be reduced by 30% using high strength steel in combination with innovative production methods like roll forming.展开更多
基金Supported by National Science and Technology Major Project(Grant No.2015ZX04014021)
文摘A light?weight design method of integrated structural topology and size co?optimization for the force?performance?structure of complex structural parts is presented in this paper. Firstly, the supporting function of a complex structural part is built to map the force transmission, where the force exerted areas and constraints are considered as connecting structure and the structural configuration, to determine the part performance as well as the force routines. Then the connecting structure design model, aiming to optimize the static and dynamic performances on connection configuration, is developed, and the optimum design of the characteristic parameters is carried out by means of the collaborative optimization method, namely, the integrated structural topology optimization and size optimization. In this design model, the objective is to maximize the connecting stiffness. Based on the relationship between the force and the structural configuration of a part, the optimal force transmission routine that can meet the performance requirements is obtained using the structural topology optimization technology. Accordingly, the light?weight design of conceptual configuration for complex parts under multi?objective and multi?condition can be realized. Finally, based on the proposed collaborative optimization design method, the optimal performance and optimal structure of the complex parts with light weight are realized, and the reasonable structural unit configuration and size charac?teristic parameters are obtained. A bed structure of gantry?type machining center is designed by using the proposed light?weight structure design method in this paper, as an illustrative example. The bed after the design optimization is lighter 8% than original one, and the rail deformation is reduced by 5%. Moreover, the lightweight design of the bed is achieved with enhanced performance to show the effectiveness of the proposed method.
基金supported by the National Natural Science Foundation of China(11372060,10902018,91216201,and 11326005)the National Basic Research Program of China(2011CB610304)the Major National Science and Technology Project(2011ZX02403-002)
文摘The size effects of microstructure of lattice materials on structural analysis and minimum weight design are studied with extented multiscale finite element method（EMsFEM） in the paper. With the same volume of base material and configuration, the structural displacement and maximum axial stress of micro-rod of lattice structures with different sizes of microstructure are analyzed and compared.It is pointed out that different from the traditional mathematical homogenization method, EMsFEM is suitable for analyzing the structures which is constituted with lattice materials and composed of quantities of finite-sized micro-rods.The minimum weight design of structures composed of lattice material is studied with downscaling calculation of EMsFEM under stress constraints of micro-rods. The optimal design results show that the weight of the structure increases with the decrease of the size of basic sub-unit cells. The paper presents a new approach for analysis and optimization of lattice materials in complex engineering constructions.
基金Project supported by the National Natural Science Foundation of China(Nos.11172089 and 11372095)the State Key Laboratory of Mechanics and Control of Mechanical Structures(Nos.MCMS-0212G01 and MCMS-0215G01)
文摘The woven textile sandwich composite（WTSC） is a promising lightweight composite.In bending,two competing core shearing failure modes reduce the strength;deflection induced by the core shearing deformation reduces the flexural rigidity.To replace a solid composite laminate,the span of WTSC panel must be greater than a critical value,which was deduced on the condition that the load capacity and flexural rigidity of the WTSC panel are equal to those of the composite laminate.Three WTSC panels were tested in bending,so that the failure modes were observed,and the critical spans were determined.Using the alternative design method,the WTSC based wind deflector with reduced weight has been fabricated and mounted on the CRH（China Railway High-speed）.
文摘This paper focuses on an estimation of light weighting opportunities for the frame structure of com- mercial road vehicles. This estimation is based on simpli- fied static load cases which play a predominant role for the dimensioning of a frame structure and therefore these simplifications are not putting the general validity of the conclusions into question. A comparison of different ma- terials under this scenario shows that light metals do not show any weight reduction advantage in comparison to steel while a material-independent topology optimization has more weight reduction potential for the frame structure than a simple change of materials. Considering the con- straints of part complexity which is directly linked with production and assembly cost, the ladder frame structure has become the current state of the art design. Thus the paper also puts a spotlight on basic rules of node design and vertical load induction in order to keep the weight of such a design as low as possible. Practical examples from manufacturers show that the weight of a commercial vehicle could be reduced by 10%, and main parts of the frame structure could be reduced by 30% using high strength steel in combination with innovative production methods like roll forming.
