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Optimization assisted redesigning a structure of a hydrogen valve: the redesign process and numerical evaluations

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Abstract

This study introduced the redesign process of an automotive hydrogen valve. The process relied on the structural optimization approach, which used to build up the new valves having promising stiffness and the lowest possible weights. To achieve the goals, the study was proposed to be taken place via the three main stages. These stages included topology optimization, lattice optimization, as well as numerical evaluations. The achieved results firstly indicated that the two newly designed valves possessed longer life and lower mass than the original valve. Especially, the topology optimized one could withstand more than 5E4 working cycles in the pre-treated condition before the first crack would be nucleated. The results also pointed out the influences of the pre-treatment pressure on the fatigue performance of the hydrogen valve. Within the examined ranges of the pressure, increasing the pressure’s magnitudes tended to shorten the fatigue life of the topology optimized valve. Additionally, the results highlighted the impact of the employed materials on the estimated fatigue life of such a non-treated structure. In the highlights, the considered steel valves could function normally far beyond 1.5E5 working cycles while the aluminum valves would have an initial crack formation prior to reaching 3E3 cycles. The results also suggested that further practical evidence is needed to not only confirm whether the selected printed aluminum is among the promising candidate materials of the hydrogen valve but also to support the described evaluations.

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Abbreviations

\( b \) :

Fatigue strength exponent

\( c \) :

Fatigue ductility exponent

\( E \) :

Elastic modulus

\( K \) :

Real stiffness matrix of elements

\( \tilde{K} \) :

Penalized stiffness matrix

\( K_{TREAT} \) :

Surface treatment factor

\( K_{USER} \) :

User surface factor

\( N_{f} \) :

Half number of reversals to failure

\( P \) :

Factor for penalization

\( R_{a} \) :

Surface roughness

\( S \) :

Material constant

\( \gamma_{max} \) :

Maximal shear strain amplitude on critical plane

\( \delta \varepsilon_{n} \) :

Normal strain range on maximal shear strain plane

\( \tilde{\varepsilon } \) :

Path-independent damage parameter (Wang-Brown)

\( \varepsilon_{f}^{\prime } \) :

Fatigue ductility coefficient

\( \vartheta \) :

Poisson ratio

\( \vartheta^{\prime } \) :

Effective Poisson ratio

\( \rho \) :

Element density

\( \sigma_{f}^{'} \) :

Fatigue strength coefficient

\( \sigma_{n, mean} \) :

Mean stress normal to maximal shear strain plane

AF:

Autofrettage

CAD:

Computer-aided design

DMLS:

Direct metal laser sintering

EN:

Strain-fife

FE:

Finite element

FSO:

Free shape optimization

GBES:

General body element size

LO:

Lattice optimization

LV2:

Lattice valve – version 2

MAM:

Metal-based additive manufacturing

MES:

Minimal element size

OV:

Original valve

PHSS:

Precipitation hardening stainless steel

SIMP:

Solid isotropic material with penalization

TNoE:

Total number of elements

TO:

Topology optimization

TPRD:

Thermal pressure release device

WB-mean:

Wang-Brown method with mean stress correction

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Acknowledgements

The authors would like to acknowledge the financial support, provided by the University of Luxembourg. They would also like to give the sincere thanks to ROTAREX S. A. for sharing the original model of the hydrogen valve.

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Authors and Affiliations

  1. Department of Engineering, Faculty of Science, Technology and medicine, University of Luxembourg, Campus Kirchberg, 6, rue Richard Coudenhove-Kalergi, 1359, Luxembourg, Luxembourg

    Thanh Binh Cao, Slawomir Kedziora & Christian Repplinger

  2. Rotarex S. A., 7440, Lintgen, Luxembourg

    Stephan Sellen

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  1. Thanh Binh Cao
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Correspondence to Thanh Binh Cao.

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Cao, T.B., Kedziora, S., Sellen, S. et al. Optimization assisted redesigning a structure of a hydrogen valve: the redesign process and numerical evaluations. Int J Interact Des Manuf 14, 613–629 (2020). https://doi.org/10.1007/s12008-020-00648-x

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