薄壁构件与桁架结构的抗撞性优化研究
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摘要
汽车碰撞安全性是现代汽车工业研究的最关键内容之一,而如何提高汽车在碰撞事故中的抗撞性能是汽车安全性能设计中的核心问题。作为最传统、最有效的吸能元件---金属薄壁构件,在车身吸能装置中已得到了广泛的应用,但其吸能性能不仅与构件的材料性能有关,而且与构件的截面形状和几何尺寸、触发方式和加载条件等因素紧密相关。因此,研究车身中抗撞性构件与上述因素之间的关系将对汽车碰撞安全性的设计起到至关重要的指导作用,具有十分重要的工程意义和学术价值。由于车身结构多为框架结构,根据轻量化要求,在抗撞性能不变的情况下,如何减小框架结构的质量也是学者关心的课题。本文在已有研究的基础上,基于有限元仿真技术,响应面近似理论和渐进结构优化法对薄壁构件和框架结构进行抗撞性优化和设计。
基于已有的抗撞性优化问题的研究,综述了薄壁构件抗撞性的理论与仿真研究现状、薄壁构件抗撞性优化研究现状和桁架结构的拓扑研究现状。为了克服构件碰撞仿真数值优化中数值分析的不稳定性、不确定性和高度非线性等技术难题,本文采用了代理模型理论和与之相应的优化方法,结合现有商业碰撞仿真分析软件,提出了针对汽车碰撞安全性的优化方法和优化流程。基于上述优化流程,以汽车前纵梁前端的薄壁方管为吸能元件,从吸能能力和轻量化角度出发,以比吸能为优化目标函数,分析薄壁方管的几何参数对其比吸能的影响,并对其几何参数进行优化。
基于安全性和轻量化的设计理念,以汽车前纵梁前端的薄壁方管吸能元件为研究对象,在方形截面薄壁管的基础上,设计了多元胞截面和附缘截面两种截面形状的薄壁构件,并以薄壁构件的比吸能为目标函数,基于代理模型和响应面法对两种截面模型的截面尺寸进行了抗撞性优化,分析了两种截面的几何参数对其能量吸收和比吸能的影响,得到了各个截面构件的最优化模型和参数;以部分锥形薄壁方管的安全装置作为研究对象,综合考虑薄壁管结构能量吸收、碰撞力、质量等相关优化因素,并考虑到最大碰撞力一般为初始碰撞力峰值,提出了以结构吸收的能量、比吸能和初始碰撞力峰值为多目标的抗撞性优化问题,通过理想点法来求解多目标优化问题,分析了锥形薄壁方管各几何参数对其能量吸收、比吸能和初始碰撞力峰值的影响,最终得到给定权系数下的最优模型。
基于静力学桁架结构拓扑优化理论,采用渐进结构优化方法对受冲击载荷作用下桁架结构进行拓扑优化设计。优化中使用显式有限元软件LS-DYNA分析得到桁架结构的变形和应变能,采用各梁单元应变能与最大应变能的比值为因子来决定材料的相对使用效率,采用桁架结构的比吸能来决定优化是否达到设计要求,最后给出算例,验证了渐进结构优化方法在桁架结构抗撞性拓扑问题中的可行性和有效性。
论文研究表明:在构件碰撞安全性的仿真优化设计中,本文提出的基于代理模型的优化方法和优化流程是十分有效的,依据该方法和流程,选择合适的代理模型和优化算法,能够快速、经济、准确地解决构件抗撞性优化问题;同时本文首次将渐进结构优化方法引入到碰撞问题中,验证了渐进结构优化方法解决桁架结构抗撞性拓扑优化问题的可行性和有效性,这些对汽车碰撞安全性的优化设计具有重要的参考价值和借鉴意义。
Vehicle passive safety is one of the key problems for the automobile industry. How to improve the crashworthiness of vehicles has been the key issue of the automotive safety. The thin-walled metallic components---the most conventional and effective energy-absorbed device,have been widely used in the automotive design and manufacture. The energy-absorbed characteristics of the components not only have close relation with their characteristics but also are significantly affected by other parameters such as the cross-sectional shape and geometric size of the components, and the type of trigger as well as the way of loading. Therefore, the crashworthiness research on the relationship between thin-walled metallic components and the above parameters that affect its energy-absorbed characteristics have an important guidance on the design of the automotive crash safety. And there are notable engineering significance and academic value to seek one optimal design method. Based on the existing research achievements and by use of the explicit finite element technique, response surface method and evolutionary structure optimization method, the thin-walled components and frame structures under impact load have been investigated and optimized in this thesis.
Base on the existing research achievements on the crashworthiness optimization, the recent developments of theories and simulations for thin-walled structures and frame structures are briefly summarized. In order to overcome difficulties in numerical optimization analysis such as instability, uncertainty and high nonlinearity, based on the surrogate model theory and the related optimization method as well as the crash software the optimization method and process for automotive crash safety are presented. Based on the above process, crashworthiness optimization for a thin-walled tube with uniform square section is taken as an example to test the optimization process, and the results show the feasibility and validity of this method.
In terms of the crash energy absorption and weight efficiency, a multi-cell cross-section tube and an adhesive flange cross-section tube are designed and optimized respectively. The optimization process with the target of maximizing the Specific Energy Absorption (SEA) has been successfully carried out, and the new structures show dramatic improvements over the conventional square tube. Then, the tapered thin-walled square tube is optimized. The geometric parameters of the tapered tube are chosen as design variables. The maximization of the energy absorbed by the structure, the maximization of the Specific Energy Absorption (SEA), and the minimization of the initial force peak are considered as the multi-objective functions. The objective functions are constructed based on the response surface method. The multi-objective optimization for the tapered thin-walled square tube is presented by using the ideal point method and introducing weighted coefficients characterizing the priority of each objective function in the design.
According to the theories of frame structure topological optimization under static loading, the evolutionary structure optimization method is firstly introduced into the frame structure topological optimization under impact loading. In this method, the ratio of elemental strain energy to the highest strain energy is adopted as a factor to determine the relative efficiency of material usage, and the ratio of total stain energy to total structural weight is established in order to decide whether an optimum has been reached. The feasibility and efficiency of the evolutionary structure optimization have been tested by an example of 2D-frame structure crash optimization.
The results of this thesis indicate: the optimization method and the process based on surrogate model are quite effective in the automotive crash safety. If choosing the appropriate surrogate model and optimization methodology according to the above method and process, the puzzle of the automotive passive safety optimization can be solved quickly, economically and exactly, which has a significant use in the reference to the automotive crash safety design optimization.
基于已有的抗撞性优化问题的研究,综述了薄壁构件抗撞性的理论与仿真研究现状、薄壁构件抗撞性优化研究现状和桁架结构的拓扑研究现状。为了克服构件碰撞仿真数值优化中数值分析的不稳定性、不确定性和高度非线性等技术难题,本文采用了代理模型理论和与之相应的优化方法,结合现有商业碰撞仿真分析软件,提出了针对汽车碰撞安全性的优化方法和优化流程。基于上述优化流程,以汽车前纵梁前端的薄壁方管为吸能元件,从吸能能力和轻量化角度出发,以比吸能为优化目标函数,分析薄壁方管的几何参数对其比吸能的影响,并对其几何参数进行优化。
基于安全性和轻量化的设计理念,以汽车前纵梁前端的薄壁方管吸能元件为研究对象,在方形截面薄壁管的基础上,设计了多元胞截面和附缘截面两种截面形状的薄壁构件,并以薄壁构件的比吸能为目标函数,基于代理模型和响应面法对两种截面模型的截面尺寸进行了抗撞性优化,分析了两种截面的几何参数对其能量吸收和比吸能的影响,得到了各个截面构件的最优化模型和参数;以部分锥形薄壁方管的安全装置作为研究对象,综合考虑薄壁管结构能量吸收、碰撞力、质量等相关优化因素,并考虑到最大碰撞力一般为初始碰撞力峰值,提出了以结构吸收的能量、比吸能和初始碰撞力峰值为多目标的抗撞性优化问题,通过理想点法来求解多目标优化问题,分析了锥形薄壁方管各几何参数对其能量吸收、比吸能和初始碰撞力峰值的影响,最终得到给定权系数下的最优模型。
基于静力学桁架结构拓扑优化理论,采用渐进结构优化方法对受冲击载荷作用下桁架结构进行拓扑优化设计。优化中使用显式有限元软件LS-DYNA分析得到桁架结构的变形和应变能,采用各梁单元应变能与最大应变能的比值为因子来决定材料的相对使用效率,采用桁架结构的比吸能来决定优化是否达到设计要求,最后给出算例,验证了渐进结构优化方法在桁架结构抗撞性拓扑问题中的可行性和有效性。
论文研究表明:在构件碰撞安全性的仿真优化设计中,本文提出的基于代理模型的优化方法和优化流程是十分有效的,依据该方法和流程,选择合适的代理模型和优化算法,能够快速、经济、准确地解决构件抗撞性优化问题;同时本文首次将渐进结构优化方法引入到碰撞问题中,验证了渐进结构优化方法解决桁架结构抗撞性拓扑优化问题的可行性和有效性,这些对汽车碰撞安全性的优化设计具有重要的参考价值和借鉴意义。
Vehicle passive safety is one of the key problems for the automobile industry. How to improve the crashworthiness of vehicles has been the key issue of the automotive safety. The thin-walled metallic components---the most conventional and effective energy-absorbed device,have been widely used in the automotive design and manufacture. The energy-absorbed characteristics of the components not only have close relation with their characteristics but also are significantly affected by other parameters such as the cross-sectional shape and geometric size of the components, and the type of trigger as well as the way of loading. Therefore, the crashworthiness research on the relationship between thin-walled metallic components and the above parameters that affect its energy-absorbed characteristics have an important guidance on the design of the automotive crash safety. And there are notable engineering significance and academic value to seek one optimal design method. Based on the existing research achievements and by use of the explicit finite element technique, response surface method and evolutionary structure optimization method, the thin-walled components and frame structures under impact load have been investigated and optimized in this thesis.
Base on the existing research achievements on the crashworthiness optimization, the recent developments of theories and simulations for thin-walled structures and frame structures are briefly summarized. In order to overcome difficulties in numerical optimization analysis such as instability, uncertainty and high nonlinearity, based on the surrogate model theory and the related optimization method as well as the crash software the optimization method and process for automotive crash safety are presented. Based on the above process, crashworthiness optimization for a thin-walled tube with uniform square section is taken as an example to test the optimization process, and the results show the feasibility and validity of this method.
In terms of the crash energy absorption and weight efficiency, a multi-cell cross-section tube and an adhesive flange cross-section tube are designed and optimized respectively. The optimization process with the target of maximizing the Specific Energy Absorption (SEA) has been successfully carried out, and the new structures show dramatic improvements over the conventional square tube. Then, the tapered thin-walled square tube is optimized. The geometric parameters of the tapered tube are chosen as design variables. The maximization of the energy absorbed by the structure, the maximization of the Specific Energy Absorption (SEA), and the minimization of the initial force peak are considered as the multi-objective functions. The objective functions are constructed based on the response surface method. The multi-objective optimization for the tapered thin-walled square tube is presented by using the ideal point method and introducing weighted coefficients characterizing the priority of each objective function in the design.
According to the theories of frame structure topological optimization under static loading, the evolutionary structure optimization method is firstly introduced into the frame structure topological optimization under impact loading. In this method, the ratio of elemental strain energy to the highest strain energy is adopted as a factor to determine the relative efficiency of material usage, and the ratio of total stain energy to total structural weight is established in order to decide whether an optimum has been reached. The feasibility and efficiency of the evolutionary structure optimization have been tested by an example of 2D-frame structure crash optimization.
The results of this thesis indicate: the optimization method and the process based on surrogate model are quite effective in the automotive crash safety. If choosing the appropriate surrogate model and optimization methodology according to the above method and process, the puzzle of the automotive passive safety optimization can be solved quickly, economically and exactly, which has a significant use in the reference to the automotive crash safety design optimization.
引文
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