Typical multidisciplinary design optimization（MDO） has gradually been proposed to balance performances of lightweight, noise, vibration and harshness（NVH） and safety for instrument panel（IP） structure in the aut...Typical multidisciplinary design optimization（MDO） has gradually been proposed to balance performances of lightweight, noise, vibration and harshness（NVH） and safety for instrument panel（IP） structure in the automotive development. Nevertheless, plastic constitutive relation of Polypropylene（PP） under different strain rates, has not been taken into consideration in current reliability-based and collaborative IP MDO design. In this paper, based on tensile test under different strain rates, the constitutive relation of Polypropylene material is studied. Impact simulation tests for head and knee bolster are carried out to meet the regulation of FMVSS 201 and FMVSS 208, respectively. NVH analysis is performed to obtain mainly the natural frequencies and corresponding mode shapes, while the crashworthiness analysis is employed to examine the crash behavior of IP structure. With the consideration of lightweight, NVH, head and knee bolster impact performance, design of experiment（DOE）, response surface model（RSM）, and collaborative optimization（CO） are applied to realize the determined and reliability-based optimizations, respectively. Furthermore, based on multi-objective genetic algorithm（MOGA）, the optimal Pareto sets are completed to solve the multi-objective optimization（MOO） problem. The proposed research ensures the smoothness of Pareto set, enhances the ability of engineers to make a comprehensive decision about multi-objectives and choose the optimal design, and improves the quality and efficiency of MDO.展开更多
Tubular hydroforming has attracted increased attention in the vehicle industry recently. This paper covers a complete hydroforming process design for an instrum ent panel frame by finite element simulation using the e...Tubular hydroforming has attracted increased attention in the vehicle industry recently. This paper covers a complete hydroforming process design for an instrum ent panel frame by finite element simulation using the explicit code LS-DYNA. The manufacturing process for the instrument panel frame consists of tube pre-be nding and final hydroforming. To accomplish hydroforming process design successf ully, a thorough investigation of proper combination of process parameters such as internal hydraulic pressure and axial feeding is carried out by finite element simulation to predict the tube wall thickness and shape. An optimized process parameter combination is obtained and verified by the instrument panel frame hyd roforming experiment. The experiment shows that designed process parameters can be used in real production through FEA simulation, but tubular thinned amplitu de by FEA is less than that with the experiment.展开更多
The influences of different design factors,as well as dummy posture,on an occupants' knee slider compression,were studied in this paper.Based on the vehicle geometry data,the simulation model,including both the mu...The influences of different design factors,as well as dummy posture,on an occupants' knee slider compression,were studied in this paper.Based on the vehicle geometry data,the simulation model,including both the multi-rigid-body and finite element(FE)part,was built up and validated with China New Car Assessment Program(C-NCAP)full impact to ensure the accuracy of the model.By adjusting the design parameters and the posture of the femur and lower leg,different factors affecting the passengers' knee slider compression were evaluated,with the help of MAthematical DYnamic MOdel(MADYMO)simulations.The study indicated that the leg posture,the stiffness of the IP and angles of the carpet have significant effects on the knee slider compression in this case.By decreasing the angle between the femur and lower leg from 133° to 124°,the maximum knee slider compression was decreased by 17.3% and by scaling the IP stiffness from 1 to 0.7,it could be decreased by 18.6%.Also,decreasing the angles of the carpet from 28° to 37°can help reduce the knee slider compression by 18.3%.展开更多
基金supported by National Hi-tech Research and Development Program of China(863 Program, Grant No. 2007AA04Z132)National Natural Science Foundation of China(Grant No. 51175379)
文摘Typical multidisciplinary design optimization（MDO） has gradually been proposed to balance performances of lightweight, noise, vibration and harshness（NVH） and safety for instrument panel（IP） structure in the automotive development. Nevertheless, plastic constitutive relation of Polypropylene（PP） under different strain rates, has not been taken into consideration in current reliability-based and collaborative IP MDO design. In this paper, based on tensile test under different strain rates, the constitutive relation of Polypropylene material is studied. Impact simulation tests for head and knee bolster are carried out to meet the regulation of FMVSS 201 and FMVSS 208, respectively. NVH analysis is performed to obtain mainly the natural frequencies and corresponding mode shapes, while the crashworthiness analysis is employed to examine the crash behavior of IP structure. With the consideration of lightweight, NVH, head and knee bolster impact performance, design of experiment（DOE）, response surface model（RSM）, and collaborative optimization（CO） are applied to realize the determined and reliability-based optimizations, respectively. Furthermore, based on multi-objective genetic algorithm（MOGA）, the optimal Pareto sets are completed to solve the multi-objective optimization（MOO） problem. The proposed research ensures the smoothness of Pareto set, enhances the ability of engineers to make a comprehensive decision about multi-objectives and choose the optimal design, and improves the quality and efficiency of MDO.
文摘Tubular hydroforming has attracted increased attention in the vehicle industry recently. This paper covers a complete hydroforming process design for an instrum ent panel frame by finite element simulation using the explicit code LS-DYNA. The manufacturing process for the instrument panel frame consists of tube pre-be nding and final hydroforming. To accomplish hydroforming process design successf ully, a thorough investigation of proper combination of process parameters such as internal hydraulic pressure and axial feeding is carried out by finite element simulation to predict the tube wall thickness and shape. An optimized process parameter combination is obtained and verified by the instrument panel frame hyd roforming experiment. The experiment shows that designed process parameters can be used in real production through FEA simulation, but tubular thinned amplitu de by FEA is less than that with the experiment.
基金Supported by the National Natural Science Foundation of China(51405050)Key Laboratory of Advanced Manufacturing Technology for Automobile Parts,Ministry of Education(2016KLMT03)Scientific and Technological Research Program of Chongqing Municipal Education Commission(KJ1500912)
文摘The influences of different design factors,as well as dummy posture,on an occupants' knee slider compression,were studied in this paper.Based on the vehicle geometry data,the simulation model,including both the multi-rigid-body and finite element(FE)part,was built up and validated with China New Car Assessment Program(C-NCAP)full impact to ensure the accuracy of the model.By adjusting the design parameters and the posture of the femur and lower leg,different factors affecting the passengers' knee slider compression were evaluated,with the help of MAthematical DYnamic MOdel(MADYMO)simulations.The study indicated that the leg posture,the stiffness of the IP and angles of the carpet have significant effects on the knee slider compression in this case.By decreasing the angle between the femur and lower leg from 133° to 124°,the maximum knee slider compression was decreased by 17.3% and by scaling the IP stiffness from 1 to 0.7,it could be decreased by 18.6%.Also,decreasing the angles of the carpet from 28° to 37°can help reduce the knee slider compression by 18.3%.
