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Methodology for automated designing of composite structures in suspension systems

Grünheid, Thomas and Deißer, Oliver and Sturm, Ralf (2021) Methodology for automated designing of composite structures in suspension systems. NAFEMS World Congress 2021, 25.-29. Okt. 2021, Online.

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Abstract

Composite materials in automotive structures have the potential to reduce CO2 emissions by simultaneously saving weight and improving fatigue performance. Further weight reduction potential can be obtained by integrating additional functions into composite structures. Regarding a suspension system, the control arms and coil springs in a McPherson front axle can be substituted by a transverse composite leaf spring. Designing this composite leaf spring structure with wheel controlling functionality is extremely challenging due to the high number of design parameters influencing the geometry and the laminate layer setup. In particular, large deformations due to bending of the control arm during wheel travel while preserving longitudinal and lateral stiffness and strength complicates the finding of solutions. Meta-model-based optimization methods can be used to identify solutions in the complex design space. Therefore, automation in the modelling process is essential. In the Next Generation Car project (NGC) of the German Aerospace Center (DLR), new development methods are investigated for automated designing and dimensioning by using optimization algorithms. The programmed process chain is connecting CAD, finite element and multi body simulation software is controlled by optimization software. All obtained displacements are cross-checked with the reference trajectory. The parametric CAD model and layer setup is controlled by meta-model-based optimization software. The resulting geometry is meshed and an implicit finite element model is created to directly identify the structural response. The design space of the optimizer includes different geometric designs of the composite structure and each layer of the laminate which are sized according to the load cases. To ensure elastic deformation, the Tsai-Wu criterion is applied as an optimization constraint. The first results show that the selected optimization approach has a high potential for finding structures which can achieve the desired wheel travel. The investigated process chain creates transverse leaf spring geometries with reasonable layer sequences.

Item URL in elib:https://elib.dlr.de/147675/
Document Type:Conference or Workshop Item (Speech)
Additional Information:Die Veröffentlichung enthält Inhalte aus dem Projekt GEM-EF (Ganzheitliche, vernetzte Entwicklungsmethodik für innovative elektromotorische Fahrwerkkonzepte), das zusammen mit dem Institut für Fahrzeugtechnik Stuttgart (IFS) der Universiät Stuttgart bearbeitetw wurde. Gefördert wurde das Projekt durch das Ministerium für Wirtschaft, Arbeit und Wohnungsbau Baden-Würtemberg wurde.
Title:Methodology for automated designing of composite structures in suspension systems
Authors:
AuthorsInstitution or Email of AuthorsAuthor's ORCID iD
Grünheid, ThomasThomas.Gruenheid (at) dlr.deUNSPECIFIED
Deißer, OliverOliver.Deisser (at) dlr.dehttps://orcid.org/0000-0002-7328-2761
Sturm, RalfRalf.Sturm (at) dlr.deUNSPECIFIED
Date:26 October 2021
Refereed publication:Yes
Open Access:No
Gold Open Access:No
In SCOPUS:No
In ISI Web of Science:No
Status:Published
Keywords:Composite leaf spring, Meta-model, Optimization, Chassis, Suspension
Event Title:NAFEMS World Congress 2021
Event Location:Online
Event Type:international Conference
Event Dates:25.-29. Okt. 2021
Organizer:NAFEMS
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Transport
HGF - Program Themes:Road Transport
DLR - Research area:Transport
DLR - Program:V ST Straßenverkehr
DLR - Research theme (Project):V - NGC Fahrzeugstruktur II
Location: Stuttgart
Institutes and Institutions:Institute of Vehicle Concepts
Deposited By: Grünheid, Thomas
Deposited On:16 Dec 2021 14:54
Last Modified:16 Dec 2021 14:54

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