coventry - jesper christensen

7/30/2019 Coventry - Jesper Christensen

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Optimising FEV BIW Architecture

from a Styling Envelope

Jesper ChristensenCoventry University, UK


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Agenda

Introduction

Purpose & proposed methodology

Topology optimisation

Lessons learnt

Crash structure and safety cell

Automation

Shape & size optimisation Crash structure development

Safety cell development

Automation

Conclusion and future steps


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Low Carbon Vehicle Technology Project, ongoing TARF

29 million research project

Project partners:

Introduction

Define a methodology for developing a

lightweight vehicle architecture (BIW)


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Purpose & proposed methodology

Define a methodology for developing a lightweight architecture

Requirements:

Vehicle may be Fully Electric (FE) or Hybrid Electric (HE)

How?

Conventional BIW development

O timisin re-existin BIW

Blank sheet use optimisation

.

2.Topology optimisation

3.Shape- & size optimisation

4.BIW draft

Overall aims:

Minimise BIW mass

Meet safety requirements


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1. CAD model (design envelope)

2. Topology optimisation

3. Shape- & size optimisation

4. BIW draft


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4. BIW draft

GUI Automatic topology optimisation setup - tcl

BarrierCreation

Wheel andsuspension

Auxiliarycomponents

Constraints

- m nutes mo e

30 seconds / model


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Topology Shape- & size optimisation




4. BIW draft

Safety cell


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Shape- & size optimisation




4. BIW draft


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Shape- & size optimisation




4. BIW draft

`

Crash structure


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BIW draft




4. BIW draft

Crash structure Safety cell

BIW draft


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1.CAD model (design envelope)



Conclusions:

Good for (rapid) initial BIW load path estimations Good for safety cell development

Inertia Relief Limitations of linear elastic software Interpretations of results are vital

4.BIW draft

Future steps:

Non-linear topology optimisation (ESLM?)

Joint modelling (multiple materials) Increased consideration of manufacturing constraints

Consideration of shape- and size opt. within topology opt. Combined linear and non-linear topology optimisation


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Conclusions:

Interpretations of results are vital

4.BIW draftFuture steps:

Automatic / mathematical extraction of results CAD model


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Conclusions:

Excellent for lightweight crash structure development Robust, stable and efficient response surfaces Excellent coupling with Dynamic modelling Excellent sampling point options

4.BIW draftFuture steps:

Automation / template building (as topology setup)

Direct link with topology optimisation


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Thank you for your attention any questions?

Jesper ChristensenLecturer in Stress [email protected]

Christophe BastienPrinci al Lecturer Automotive En ineerin

[email protected]

Mike V BlundellProfessor of Vehicle Dynamics & [email protected]

coventry - jesper christensen

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