Based On Crashworthiness Topology Optimization Of The Key Automotive Safety Component Design

With the rapid development of the auto industry in our country, China hasbecome the primary country for automobile production and sale, but traffic accidentsand the resulting casualties and property losses also increased markedly as theincrement of vehicle magnitude and driving speed at the same time. With increasingawareness of vehicle safety performance, the car’s safety performance equivalent tocomfort and dynamic economy to become one of the important performance whenpeople a car. In order to meeting the laws and regulations about of the vehicle`s safetyperformance, and meeting the market demands of the consumer， vehiclemanufacturers more and more attention to the structural design of the vehicle crashsafety.In the concept phase of vehicle`s development，topology optimization methodscan effectively identify the best collision load path，contribute to the vehicle’s crashsafety performance improvement. This paper discussed the crashworthiness topologyoptimization method base on LS-DYNA explicit FEM， and presented themathematical model of the iterative solution.This paper based on the actual project, the object study by one of the design anddevelopment stage vehicle, crashworthiness topology optimization method is appliedto the vehicle`s development process. Against with the poor performance of thevehicle frontal collision, combined with the crushing theory of the thin-walled tube,and material distribution from topology optimization results and practical engineeringfactors, to guide the initial design of the main energy absorbing part in front cabin. Inorder to solving the large amount of invade in the side collision and threshold beambending phenomenon in the offset collision, establishing the threshold beam’s offsetcollision and side impact parallel computation topology optimization model，according to optimize the results of material distribution engineering interpretation.Verify that result of the engineering interpretation in the finite element model ofvehicle collisions. The results show that: In the frontal collision, the energy-absorbingutilization of front cabin is increased, reduced the effective acceleration; In the offsetcollision, the threshold beam`s crushing amount of X vector reduce from20.3mm to13.8mm; In the side collision, B pillar with respect to the dummy pelvis positioninvasive reduced by11.5%, the penetration speed reduced by6.5%, playing a vital role for protecting the passengers in vehicles.Finally, discuss the crashworthiness topology optimization method in the actualdesign of the vehicle.