Structural and Multidisciplinary Optimization

, Volume 53, Issue 4, pp 923–934 | Cite as

Spot weld reduction methods for automotive structures

INDUSTRIAL APPLICATION
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Abstract

Spot welds are commonly used to join steel sheets in automotive structures. The number and layout of these spot welds are vital for the performance of the structure. However, reducing the number of spot welds will cut both production time and cost. This article presents three different methods of reducing the number of spot welds in automotive structures: ranking-based selection, topology optimization and size optimization of a parameterized model. The methods are compared in a simple example and it is found that the latter two methods have the best potential of reducing the number of spot welds. Topology optimization requires less preparation and computational effort as compared to size optimization of a parameterized model. However, the method is primarily suitable for studies where load cases involving linear systems are judged to be most important. Otherwise, size optimization of a parameterized model is probably a better choice. The topology optimization approach is successfully demonstrated in a full-scale industrial application example and confirms that the method is useful within contemporary product development.

Keywords

Spot weld optimization Multidisciplinary design optimization (MDO) Topology optimization Size optimization Metamodels Automotive structures 
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Notes

Acknowledgments

The authors would like to thank Qoros Automotive for their support in this study and for providing the finite element models for the industrial application example. The work presented in this article has been carried out with financial support from the Vinnova FFI project ‘Robust and multidisciplinary design optimization of automotive structures’.

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Copyright information

© Springer-Verlag Berlin Heidelberg 2015

Authors and Affiliations

  1. 1.Combitech ABTrollhättanSweden
  2. 2.Division of Solid MechanicsLinköping UniversityLinköpingSweden

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