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<p>This research presents a beam model-based fast optimization for the design of a lightweight car body frame at a concept design stage. Because the stiffness of a thin-walled beam frame is significantly affected by the stiffness of joints, the optimization is focused on the reinforcement of joint regions. To overcome the limitations of beam elements in accurately predicting the stiffness of a thin-walled beam frame, especially at joints, a higher-order beam theory (HOBT) is employed for beam modeling. The optimization problems are formulated as mean compliance minimization problems by employing two types of design components: joint springs and diaphragms. Instead of using the geometric parameters of joints as design variables, the directional stiffnesses of joint springs are employed as design variables. Joint reinforcement used for optimization is defined as a virtual part that has stiffness only against bending and torsional deformation, with zero stiffness against higher-order deformations such as warping or distortion. This approach facilitates the calculation of mass increase due to joint springs during optimization. The optimized results of joint springs are inversely designed to sectional shapes of reinforcement through topology optimization. The use of a diaphragm at a joint effectively suppresses the sectional distortion of thin-walled beams and significantly increases their stiffness. The locations of diaphragms are determined through optimization using a 0–1 formulation. The validity of the proposed optimization method is shown by solving subframe and car body frame problems. Joint reinforcement optimization of a car body frame with a 2.5% mass increase and the addition of 6 diaphragms reduced compliance by 13.88% and increased natural frequencies by up to 7.64%.</p>

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Optimization of joint reinforcement in beam model-based car body design during the conceptual stage

  • 期刊论文

  • 发表日期：

    2025年4月1日

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  • Mohammad Ali Yaqteen,
  • Gyu-Sik Kim,
  • Jin Hong Kim,
  • Jae Kap Joo,
  • Gang-Won Jang

摘要

This research presents a beam model-based fast optimization for the design of a lightweight car body frame at a concept design stage. Because the stiffness of a thin-walled beam frame is significantly affected by the stiffness of joints, the optimization is focused on the reinforcement of joint regions. To overcome the limitations of beam elements in accurately predicting the stiffness of a thin-walled beam frame, especially at joints, a higher-order beam theory (HOBT) is employed for beam modeling. The optimization problems are formulated as mean compliance minimization problems by employing two types of design components: joint springs and diaphragms. Instead of using the geometric parameters of joints as design variables, the directional stiffnesses of joint springs are employed as design variables. Joint reinforcement used for optimization is defined as a virtual part that has stiffness only against bending and torsional deformation, with zero stiffness against higher-order deformations such as warping or distortion. This approach facilitates the calculation of mass increase due to joint springs during optimization. The optimized results of joint springs are inversely designed to sectional shapes of reinforcement through topology optimization. The use of a diaphragm at a joint effectively suppresses the sectional distortion of thin-walled beams and significantly increases their stiffness. The locations of diaphragms are determined through optimization using a 0–1 formulation. The validity of the proposed optimization method is shown by solving subframe and car body frame problems. Joint reinforcement optimization of a car body frame with a 2.5% mass increase and the addition of 6 diaphragms reduced compliance by 13.88% and increased natural frequencies by up to 7.64%.