CAE-driven design methodology for semi-autonomous product development for the next generation light weight vehicle structures

Abstract

Passenger cell assembly makes up a large percentage of the overall structural weight of the BIW-design, and hence has a high lightweight potential. The structure of the passenger cell not only ensures a “rigid-like” behavior in different crash scenarios, it also contributes to comfort and driving characteristics with a high torsional and flexural stiffness. Applying topology optimization here can facilitate developing novel light-weight floor assembly designs. However, implementing topology optimization as an integral part of the product development process requires a new methodological approach that skillfully combines CAE-tools with analogy methods and data management systems for decision making. For transforming the load paths into a structural concept, a technical evaluation methodology for decision making has been developed. Here the qualitative design parameters, such as geometry and the material grade of e.g. sheet metal profiles and reinforcements, are determined based on packaging requirements and analogy methods. In case of contradictory geometrical and material requirements, decision making is facilitated using preference matrices.