Shape and Sizing Optimization of Automotive Structures with Deterministic and Probabilistic Design Constraints
Rais-Rohani, M., Solanki, K.N., Acar, E., & Eamon, C. (2010). Shape and Sizing Optimization of Automotive Structures with Deterministic and Probabilistic Design Constraints. International Journal of Vehicle Design. 54(4), 2010.
The choice of deterministic and/or probabilistic (reliability-based) design constraints can drastically change the mathematical complexity of the corresponding structural optimisation problem. This is particularly true when the constraint functions are nonlinear and require the use of high fidelity numerical simulation of a complex physical event such as an automobile crash. In this paper, we present the results of a study on the combined shape and sizing optimisation of lightweight automotive structures while examining the effect of different design constraints and associated uncertainties on reliability and efficiency of the resulting optimum designs. Through design and analysis of computer experiments involving nonlinear transient dynamic finite element analysis of full-vehicle crash scenarios, surrogate models (metamodels) are developed for estimation of such responses as the intrusion distance and peak acceleration at different vehicle locations. The metamodel-based design methodology is applied to structural optimisation of the rail component of a passenger car. The results are used to compare the differences between single- and multi-objective optimisation solutions and to reveal the conflicting influences of design variables on crash responses constrained at more than one site. Moreover, the results offer insight on the effect of uncertainties in optimum design of vehicle structures.