Computational crashworthy optimization of partially filled aluminium foam for automotive side member
Lightweight design with good crashworthy characteristic is highly desirable in automotive industry. Frontal crashes is identified as the most often occurrence. Frontal collision occurred at an angle up to 30 degree, so called oblique, as prescribed in Federal Motor Vehicle Safety Standard is used in...
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| Format: | Thesis |
| Language: | English |
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2013
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| Online Access: | http://psasir.upm.edu.my/id/eprint/56174/ http://psasir.upm.edu.my/id/eprint/56174/1/FK%202013%20114RR.pdf |
| _version_ | 1848853008378494976 |
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| author | Mohd Salleh, Salwani |
| author_facet | Mohd Salleh, Salwani |
| author_sort | Mohd Salleh, Salwani |
| building | UPM Institutional Repository |
| collection | Online Access |
| description | Lightweight design with good crashworthy characteristic is highly desirable in automotive industry. Frontal crashes is identified as the most often occurrence. Frontal collision occurred at an angle up to 30 degree, so called oblique, as prescribed in Federal Motor Vehicle Safety Standard is used in this study. Geometry changes and material replacement is approaches used to improve the crash performances. Simulation is carried out using Ls-dyna software and optimization is done by using Sequential Quadratic Programming that is run in Matlab. The structure in this study is using aluminum and aluminum foam. The structure is partially filled to reduce the additional weight cause by the foam. Furthermore, the column thickness, foam length and foam density is varied to achieve the target.From the analysis of partially filled column, it was found that crush force efficiency (CFE) is highly affected by the loading angle unlike specific energy absorption (SEA). The initial response is however ruled by thin-walled aluminum deformation behavior. Introduction of partially filled column promotes improvement in SEA and CFE. SEA of the new design and empty column is 1237.76 J/kg and 907.28 J/kg with CFE of 0.7 and 0.5, respectively.A surrogate based optimization program developed by employing the Sequential Quadratic Programming method yield an optimum design of (t , L)* = (2.3,151.7) and (t , L)* = (1.1,199), for SEA and CFE, respectively. In three variables optimization, the optimum design for maximum SEA and CFE are (t ,L , r)* = (2.0,88.6,0.1) and (t ,L,r)* =( 1.4 , 129.6 , 0.2 ). In term of occupant safety,car associated with partially filled side member exhibit lowest index in occupant injury criteria, 496.6, 694 and 850 for HIC15, HIC36 and CSI, respectively. The results show thatthe crashworthiness performance of the structure can be improved throughintroduction of partially filled column. Using the developed programming for optimization, vehicle structures design can be practically optimized. |
| first_indexed | 2025-11-15T10:47:08Z |
| format | Thesis |
| id | upm-56174 |
| institution | Universiti Putra Malaysia |
| institution_category | Local University |
| language | English |
| last_indexed | 2025-11-15T10:47:08Z |
| publishDate | 2013 |
| recordtype | eprints |
| repository_type | Digital Repository |
| spelling | upm-561742017-07-20T10:47:36Z http://psasir.upm.edu.my/id/eprint/56174/ Computational crashworthy optimization of partially filled aluminium foam for automotive side member Mohd Salleh, Salwani Lightweight design with good crashworthy characteristic is highly desirable in automotive industry. Frontal crashes is identified as the most often occurrence. Frontal collision occurred at an angle up to 30 degree, so called oblique, as prescribed in Federal Motor Vehicle Safety Standard is used in this study. Geometry changes and material replacement is approaches used to improve the crash performances. Simulation is carried out using Ls-dyna software and optimization is done by using Sequential Quadratic Programming that is run in Matlab. The structure in this study is using aluminum and aluminum foam. The structure is partially filled to reduce the additional weight cause by the foam. Furthermore, the column thickness, foam length and foam density is varied to achieve the target.From the analysis of partially filled column, it was found that crush force efficiency (CFE) is highly affected by the loading angle unlike specific energy absorption (SEA). The initial response is however ruled by thin-walled aluminum deformation behavior. Introduction of partially filled column promotes improvement in SEA and CFE. SEA of the new design and empty column is 1237.76 J/kg and 907.28 J/kg with CFE of 0.7 and 0.5, respectively.A surrogate based optimization program developed by employing the Sequential Quadratic Programming method yield an optimum design of (t , L)* = (2.3,151.7) and (t , L)* = (1.1,199), for SEA and CFE, respectively. In three variables optimization, the optimum design for maximum SEA and CFE are (t ,L , r)* = (2.0,88.6,0.1) and (t ,L,r)* =( 1.4 , 129.6 , 0.2 ). In term of occupant safety,car associated with partially filled side member exhibit lowest index in occupant injury criteria, 496.6, 694 and 850 for HIC15, HIC36 and CSI, respectively. The results show thatthe crashworthiness performance of the structure can be improved throughintroduction of partially filled column. Using the developed programming for optimization, vehicle structures design can be practically optimized. 2013-06 Thesis NonPeerReviewed application/pdf en http://psasir.upm.edu.my/id/eprint/56174/1/FK%202013%20114RR.pdf Mohd Salleh, Salwani (2013) Computational crashworthy optimization of partially filled aluminium foam for automotive side member. PhD thesis, Universiti Putra Malaysia. Automobile industry and trade Vehicles - Safety measures Vehicles |
| spellingShingle | Automobile industry and trade Vehicles - Safety measures Vehicles Mohd Salleh, Salwani Computational crashworthy optimization of partially filled aluminium foam for automotive side member |
| title | Computational crashworthy optimization of partially filled aluminium foam for automotive side member |
| title_full | Computational crashworthy optimization of partially filled aluminium foam for automotive side member |
| title_fullStr | Computational crashworthy optimization of partially filled aluminium foam for automotive side member |
| title_full_unstemmed | Computational crashworthy optimization of partially filled aluminium foam for automotive side member |
| title_short | Computational crashworthy optimization of partially filled aluminium foam for automotive side member |
| title_sort | computational crashworthy optimization of partially filled aluminium foam for automotive side member |
| topic | Automobile industry and trade Vehicles - Safety measures Vehicles |
| url | http://psasir.upm.edu.my/id/eprint/56174/ http://psasir.upm.edu.my/id/eprint/56174/1/FK%202013%20114RR.pdf |