A new approach for optimizing automotive crashworthiness: concurrent usage of ANFIS and Taguchi method

Design optimization is presented for the crashworthiness improvement of an automotive body structure. The optimization objective was to improve automotive crashworthiness conditions according to the defined criterion (occupant chest deceleration) during a full frontal impact. The controllable factors used in this study consisted of six internal parts of the vehicle's frontal structure in a condition that their thickness was the "design parameter". First using the Taguchi method, this study analyzed the optimum conditions in discontinuous design area and impact factors and their optimal levels of design objectives were obtained by analyzing the experimental results. Next to model a precise understanding of the explicit mathematical input-output relationship, fuzzy logic is utilized which make use of full factorial design set of experimental test cases resulted from Taguchi predicting formulations. Interestingly, the optimum conditions for automotive crashworthiness occurred with 2.72 % improvement in the defined crashworthiness criterion in comparison with the baseline design while selected structural parts experienced mass reduction by 8.23 %

Multiobjective crashworthiness optimization of multi-cornered thin-walled sheet metal members

Plastic deformation of structures absorbs substantial kinetic energy when impact occurs. Therefore, energy-absorbing components have been extensively used in structural designs to intentionally absorb a large portion of crash energy. On the other hand, high peak crushing force, especially with regard to mean crushing force, may lead to a certain extent and indicate the risk of structural integrity. Thus, maximizing energy absorption and minimizing peak to mean force ratio by seeking for the optimal design of these components are of great significance. Along with this analysis, the collapse behavior of square, hexagonal, and octagonal cross-sections as the baseline for designing a newly introduced 12- edge section for stable collapse with high energy absorption capacity was characterized. Inherent dissipation of the energy from severe deformations at the corners of a section under axial collapse formed the basis of this study, in which multi-cornered thin-walled sections was focused on. Sampling designs of the sections using design of experiments (DOE) based on Taguchi method along with CAE simulations was performed to evaluate the responses over a range of steels grades starting from low end mild steels to high end strength. The optimization process with the target of maximizing both specific energy absorption (SEA) and crush force efficiency (CFE), as the ratio of mean crushing load to peak load, was carried out by nonlinear infinite element analysis through LS-DYNA. Based on single-objective and multi-objective optimizations, it was found that octagonal and 12-edge sections had the best crashworthiness performance in terms of maximum SEA and CFE