Lightweight Design And Optimization Of Automotive Door Based On The New Type Blanks

Along with the rapid growth of vehicle’s quantity in China, both energy shortage and environment pollution become seriously. The importance of energy saving and environment protection causes more and more attention. Weight lightening is one of the most feasible ways for energy conservation. As an important part of the vehicle, the door has great potential to be lightweight. And the lightweight research method of doors has important implications for the study about vehicle’s weight reduction.The main load bearing position of inner panel is known through the FE analysis on static stiffness performance, according to which the inner panel is "divided" into several blocks. To design the inner panel with Tailor Welded Blanks and Tailor Rolled Blanks is a suitable solution to be lightweight, analysis shows. TWB and TRB are new lightweight blanks, and it will reduce the vehicle’ weight by applying them to automobile manufacturing. Hyper Works, MATLAB, together with orthogonal test, Reliability Surface Method are used, in the thesis, to optimize the design of the inner panel made by TWB and TRB. And the goal of weight reduction is reached. TWB is used to design the inner panel first. The thicknesses of each blank and all the welds are optimized to get the best value of them, at last the weight of the door optimized is reduced by9.95percent.TRB is applied to design then. The thicknesses of each area, as well as the position and length of the transition are optimized to get the best value, and the weight of the door optimized is reduced by14.9%.The research results show:It is able to reduce the weight that either TWB or TRB is adopted by designing the door. And as for the effect on lightweight, TRB is better.