Crashworthiness Study Of Vehicle Energy Absorption Components Topology Optimization

Energy conservation, safety and environmental protection increasingly become a focus with the development of automobile industry. Vehicle frontal crash safety is a very important part of the vehicle passive safety. When vehicle head-on collision occurs, frontal energy-absorbing components of the car are main bearing and force transmission structures which directly related to the properties and the integrity of the cap and will pass the collision force and acceleration to occupants. Therefore, crashworthiness study of vehicle energy-absorbing components in the frontal crash case has very important significance.This article is mainly carry out crashworthiness study of frontal energy-absorbing components of the car based on topology optimization method. In view of the Ford Explorer model analysis, make topology optimization and size optimization of front rail and bumper, and applied the optimization results which have been verified to the vehicle. In this paper, the main research content and the work are as follows:1. Based on measurement of large number actual vehicle energy-absorption beams, dynamic topology optimization of straight beams which have different initial cross section, length and material are studied. The best cross section shape and the position of induction of straight beams are obtained under different conditions, which provides references for the future design of vehicle straight beam.2. In view of the Ford Explorer parts energy absorption, select front rail and bumper for topology optimization study of crashworthiness. In this paper, innovatively combine static and dynamic topology optimization method for crashworthiness topology optimization of automobile front rail. Through analyzing the topology optimization results and comprehensively considering axial stiffness, lateral stiffness and energy absorption characteristics, the optimal cross section form and the induced-structure size and location of the front rail will be obtained. Carry on the dynamic topology optimization to get the optimum structure form of bumper. It is concluded that the concrete thickness size of each part of aluminum alloy front rail and bumper through size optimization.3. Comparing energy-absorption based on simulation, it turn out that the specific energy-absorption of the optimized aluminum alloy front rail is 3.7 times than that of the original steel front rail. The biggest impact force decreased by 32.77% and the mass of the single front rail reduced 2.59 kg. The Specific energy absorption of the optimized aluminum alloy bumper is 3.2 times than that of the original steel bumper and the mass reduced 2.51 kg. Apply the optimized front rail and bumper to the ford explorer and analyze the vehicle front 100% overlap rate rigid wall collision simulation, the result show that the crashworthiness of the vehicle has been improved.