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Crashworthiness design of vehicle structure with tailor rolled blank

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Abstract

Lightweight and crashworthiness design have been two main challenges in the vehicle industry. These two performances often conflict with each other. To not sacrifice vehicle crashworthiness performance when performing vehicle lightweight design, a novel inner part of front longitudinal beam (FLB-inner) structure with a tailor rolled blank (TRB) concept is proposed in this work, and the corresponding design method is also proposed to minimize the weight of FLB-inner. Firstly, a full-scale vehicle finite element model is adopted and experimentally verified. Secondly, the conventional uniform thickness FLB-inner panel is replaced with a TRB structure, herein, the FLB-inner is divided into four segments with different thickness according to the crashworthiness requirements of frontal impact. Then the material constitutive model and finite element modeling for TRB is established. Thirdly, the optimal Latin hypercube sampling (OLHS) technique is used to generate sampling points and the objective and constraints function values are calculated using commercial software LS-DYNA. Based on the simulation results, the ε-SVR surrogate models are constructed. Finally, the artificial bee colony (ABC) algorithm is applied to obtain the optimal thickness distribution of FLB-inner. The results indicated that the weight of the FLB-inner is reduced by 15.21 %, while the crashworthiness is mproved in comparison with the baseline design.

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Abbreviations

TRB:

Tailor rolled blank

TWB:

Tailor welded blank

CTZ:

Constant thickness zone

TTZ:

Thickness transition zone

FLB:

Front longitudinal beam

CLB:

Center longitudinal beam

FLB-inner:

Inner part of the front longitudinal beam

FLB-TRB:

Front longitudinal beam with TRB

TRB FLB-inner:

Inner part of front longitudinal beam with TRB

EA:

Energy absorption

UHSS:

Ultra high strength steel

AHSS:

Advanced high strength steel

OLHS:

Optimal Latin hypercube sampling

ABC:

Artificial bee colony

FSV:

Future Steel Vehicle

MDO:

Multidisciplinary design optimization

BIW:

Body-in-white

RSM:

Response surface models

RBF:

Radial basis functions

MARS:

Multivariate adaptive regression splines

KG:

Kriging

SVR:

Support vector regression

ε-SVR:

ε-support vector regression

ν-SVR:

ν-support vector regression

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Acknowledgments

This work was supported from The Key Project of National Natural Science Foundation of China (61232014) and the Program of NSFC of China (11202072), The Doctoral Fund of Ministry of Education of China (20120161120005), The Open Fund Program of the State Key Laboratory of Vehicle Light-weight Design, P. R. China (20130303) and the Hunan Provincial Science Foundation of China (13JJ4036).

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Authors and Affiliations

  1. State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, Hunan University, Changsha, 410082, China

    Libin Duan, Guangyong Sun, Junjia Cui, Tao Chen, Aiguo Cheng & Guangyao Li

  2. Collaborative Innovation Center of Intelligent New Energy Vehicle, Shanghai, 200092, China

    Libin Duan, Guangyong Sun, Junjia Cui, Tao Chen, Aiguo Cheng & Guangyao Li

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  1. Libin Duan
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  2. Guangyong Sun
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Correspondence to Aiguo Cheng or Guangyao Li.

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Duan, L., Sun, G., Cui, J. et al. Crashworthiness design of vehicle structure with tailor rolled blank. Struct Multidisc Optim 53, 321–338 (2016). https://doi.org/10.1007/s00158-015-1315-z

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