Team of the chair
Dr. - Ing. Philipp Clemens
Research assistant
Biography
Topology and Shape Optimization of Deep Draw Sheet Metal Parts in Crash
In this dissertation, an optimization method is presented that enables the efficient optimization of deep-drawing sheet metal components subjected to crash loads. The optimization is divided into an inner and an outer loop. In the outer loop, a crash calculation is performed. The contact forces determined in this crash calculation are used as substitute load cases for a static linear analysis of the problem. In the inner loop, a
simultaneous shape and topology optimization using the gradient-based density method is performed for the generated static linear substitute problem. This enables an efficient optimization of the structure with the static linear analysis approximating the real structural behavior. By using a manufacturing restriction, the result of the inner loop is always a sheet metal design without undercuts in a fixed stamping direction.
To perform simultaneous shape and topology optimization, a voxel model of the design space is optimized in the inner loop. The result of this optimization is then automatically transferred to a shell model in the outer loop, before another crash calculation is performed and the process repeats. Through the outer loop, the actual crash properties are repeatedly determined, thereby verifying the results from the inner loop.
The optimization method developed here is capable of significantly reducing the intrusion of an impactor during a crash event with a reasonable computational effort, without increasing the mass of the component. However, this is not successful with all models studied. Particularly with initial designs that are already very good, the method has difficulty achieving further improvements. Suitable substitute objective functions
in the inner loop include the minimization of the mean compliance and the maximization of the buckling safety. As of the current state of this work, the optimization method developed here is limited to the reduction of intrusion.
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