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<p>Current research on crashworthiness predominantly concentrates on the design of thin-walled structures for frontal collisions, while studies on side impacts remain comparatively sparse. Functionally graded lattice structures have emerged as a promising solution for lightweight and energy-efficient design. In this study, a novel B-pillar configuration was developed by replacing the conventional reinforcement plate with a functionally graded lattice-filled dual-hat beam. The bending energy absorption behavior was evaluated through numerical simulations and validated by drop hammer impact tests. A surrogate model was constructed using design of experiments, and multi-objective optimization was performed via the NSGA-II algorithm. The final optimal design parameters were t<sub>1</sub> = 0.93&#xa0;mm, t<sub>2</sub> = 1.01&#xa0;mm, t<sub>3</sub> = 1.92&#xa0;mm, and ϖ = 1.344. The optimized B-pillar achieved an intrusion of 65.344&#xa0;mm, an intrusion velocity of 1395.41&#xa0;mm/s, and a total mass of 5.975&#xa0;kg. These correspond to a 31.01% mass reduction, with 8.26% and 25.69% decreases in maximum intrusion and intrusion velocity, respectively, compared to the original design. The discrepancy between the optimization predictions and post-optimization simulation results was less than 15%, confirming the accuracy and robustness of the optimization framework. The results demonstrate significant improvements in both crashworthiness and lightweight performance under side-impact conditions.</p>

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Functionally graded lattice structures for lightweight automotive b-pillar design

  • 期刊论文

  • 发表日期：

    2026年1月6日

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  • Hongfeng Li,
  • Yuan Fang,
  • Ben Yuan,
  • Zhibo Duan,
  • Xiaolei Zhu,
  • Xiaofeng Lu

摘要

Current research on crashworthiness predominantly concentrates on the design of thin-walled structures for frontal collisions, while studies on side impacts remain comparatively sparse. Functionally graded lattice structures have emerged as a promising solution for lightweight and energy-efficient design. In this study, a novel B-pillar configuration was developed by replacing the conventional reinforcement plate with a functionally graded lattice-filled dual-hat beam. The bending energy absorption behavior was evaluated through numerical simulations and validated by drop hammer impact tests. A surrogate model was constructed using design of experiments, and multi-objective optimization was performed via the NSGA-II algorithm. The final optimal design parameters were t1 = 0.93 mm, t2 = 1.01 mm, t3 = 1.92 mm, and ϖ = 1.344. The optimized B-pillar achieved an intrusion of 65.344 mm, an intrusion velocity of 1395.41 mm/s, and a total mass of 5.975 kg. These correspond to a 31.01% mass reduction, with 8.26% and 25.69% decreases in maximum intrusion and intrusion velocity, respectively, compared to the original design. The discrepancy between the optimization predictions and post-optimization simulation results was less than 15%, confirming the accuracy and robustness of the optimization framework. The results demonstrate significant improvements in both crashworthiness and lightweight performance under side-impact conditions.