Structural optimization of automotive chassis: theory, set up, - PowerPoint PPT Presentation

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions Structural optimization of automotive chassis: theory, set up, design M. Cavazzuti L. Splendi L. D’Agostino E. Torricelli D. Costi A. Baldini MilleChili Lab, Universit` a di Modena e Reggio Emilia, Modena, Italy PICOF 2012 6 th International Conference Probl` emes Inverses, Contrˆ ole et Optimisation de Formes Ecole Polytechnique, Palaiseau, France, April 2 nd -4 th Structural optimization of automotive chassis MilleChili Lab — PICOF’12 M. Cavazzuti, L. Splendi et al.

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions Outline Introduction 1 Structural optimization 2 Application examples 3 Automotive hood 4 Rear bench 5 Automotive chassis 6 Conclusions 7 Structural optimization of automotive chassis MilleChili Lab — PICOF’12 M. Cavazzuti, L. Splendi et al.

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions Outline Introduction 1 Structural optimization 2 Application examples 3 Automotive hood 4 Rear bench 5 Automotive chassis 6 Conclusions 7 Structural optimization of automotive chassis MilleChili Lab — PICOF’12 M. Cavazzuti, L. Splendi et al.

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions MilleChili Lab and aim of the research MilleChili Lab MilleChili Lab was born in february 2009 from a collaboration between Ferrari SpA and the Universit` a degli Studi di Modena e Reggio Emilia Objectives of the laboratory Design a novel automotive chassis in view of weight reduction and in fulfilment of given structural performance constraints according to Ferrari standards Offer a consulting service supporting Ferrari designers in the field of structural optimization of automotive components Structural optimization of automotive chassis MilleChili Lab — PICOF’12 M. Cavazzuti, L. Splendi et al.

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions MilleChili Lab rationale and main tools A different approach to design company know-how and systematic design by means designer experience of optimization techniques Structural optimization techniques Topology Topometry Topography Size Shape Structural optimization of automotive chassis MilleChili Lab — PICOF’12 M. Cavazzuti, L. Splendi et al.

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions Outline Introduction 1 Structural optimization 2 Application examples 3 Automotive hood 4 Rear bench 5 Automotive chassis 6 Conclusions 7 Structural optimization of automotive chassis MilleChili Lab — PICOF’12 M. Cavazzuti, L. Splendi et al.

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions What is structural optimization? Optimization objective y = f ( � x ) variables experiment � x or simulation constraints x ) ≥ � � c ( � 0 minimize f ( � x ) x ∈D � x ) ≥ � subject to � c ( � 0 optimization algorithm Structural optimization variables (design space) FE domain (1 variable per element) experiment or simulation finite elements analysis objective mass minimization constraints stiffness, displacements, modal, . . . optimization algorithm gradient based (CONLIN or MMA) Structural optimization of automotive chassis MilleChili Lab — PICOF’12 M. Cavazzuti, L. Splendi et al.

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions What is structural optimization? Optimization objective y = f ( � x ) variables experiment � x or simulation constraints x ) ≥ � � c ( � 0 minimize f ( � x ) x ∈D � x ) ≥ � subject to � c ( � 0 optimization algorithm Structural optimization variables (design space) FE domain (1 variable per element) experiment or simulation finite elements analysis objective mass minimization constraints stiffness, displacements, modal, . . . optimization algorithm gradient based (CONLIN or MMA) Structural optimization of automotive chassis MilleChili Lab — PICOF’12 M. Cavazzuti, L. Splendi et al.

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions What is structural optimization? Optimization objective y = f ( � x ) variables experiment � x or simulation constraints x ) ≥ � � c ( � 0 minimize f ( � x ) x ∈D � x ) ≥ � subject to � c ( � 0 optimization algorithm Structural optimization variables (design space) FE domain (1 variable per element) experiment or simulation finite elements analysis objective mass minimization constraints stiffness, displacements, modal, . . . optimization algorithm gradient based (CONLIN or MMA) Structural optimization of automotive chassis MilleChili Lab — PICOF’12 M. Cavazzuti, L. Splendi et al.

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions What is structural optimization? Optimization objective y = f ( � x ) variables experiment � x or simulation constraints x ) ≥ � � c ( � 0 minimize f ( � x ) x ∈D � x ) ≥ � subject to � c ( � 0 optimization algorithm Structural optimization variables (design space) FE domain (1 variable per element) experiment or simulation finite elements analysis objective mass minimization constraints stiffness, displacements, modal, . . . optimization algorithm gradient based (CONLIN or MMA) Structural optimization of automotive chassis MilleChili Lab — PICOF’12 M. Cavazzuti, L. Splendi et al.

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions What is structural optimization? Optimization objective y = f ( � x ) variables experiment � x or simulation constraints x ) ≥ � � c ( � 0 minimize f ( � x ) x ∈D � x ) ≥ � subject to � c ( � 0 optimization algorithm Structural optimization variables (design space) FE domain (1 variable per element) experiment or simulation finite elements analysis objective mass minimization constraints stiffness, displacements, modal, . . . optimization algorithm gradient based (CONLIN or MMA) Structural optimization of automotive chassis MilleChili Lab — PICOF’12 M. Cavazzuti, L. Splendi et al.

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions What is structural optimization? Optimization objective y = f ( � x ) variables experiment � x or simulation constraints x ) ≥ � � c ( � 0 minimize f ( � x ) x ∈D � x ) ≥ � subject to � c ( � 0 optimization algorithm Structural optimization variables (design space) FE domain (1 variable per element) experiment or simulation finite elements analysis objective mass minimization constraints stiffness, displacements, modal, . . . optimization algorithm gradient based (CONLIN or MMA) Structural optimization of automotive chassis MilleChili Lab — PICOF’12 M. Cavazzuti, L. Splendi et al.

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions Variables in structural optimization optimization method variable applicability topology element density solid & (material distribution) shell elements shell elements (deformations superposition) Structural optimization of automotive chassis MilleChili Lab — PICOF’12 M. Cavazzuti, L. Splendi et al.

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions Variables in structural optimization optimization method variable applicability topology element density solid & (material distribution) shell elements topometry element thickness shell elements (thickness distribution) (deformations superposition) Structural optimization of automotive chassis MilleChili Lab — PICOF’12 M. Cavazzuti, L. Splendi et al.

Introduction Structural optimization Application examples Automotive hood Rear bench Automotive chassis Conclusions Variables in structural optimization optimization method variable applicability topology element density solid & (material distribution) shell elements topometry element thickness shell elements (thickness distribution) topography element offset shell elements (bead patterns) (deformations superposition) Structural optimization of automotive chassis MilleChili Lab — PICOF’12 M. Cavazzuti, L. Splendi et al.