An optimization procedure for spot-welded structures based on SIMP method

Abstract

This paper proposes an optimization procedure for spot-welded structures. The welded sheets are connected through continuous solid materials instead of traditional discrete elements, and a topology optimization with Solid Isotropic Microstructure with Penalization (SIMP) method is used to remove the redundant connecting material. The current optimization procedure is able to predict an optimal number and distribution of spot welds for spot-welded structures. Applications to the double-hat welded crossbeam and D pillar joint of a body-in-white (BIW) show that the proposed optimization procedure furnishes good guidelines to redistribute spot welds in the spot-welded structures. The spot welds optimization of BIW is carried out on a finite element model. In order to verify the model, finite element analysis (FEA) and rig test of torsional stiffness are performed on the BIW, where both the FEA and rig test are carried out under the same boundary conditions. A satisfactory agreement between the FEA and experiment demonstrates the capabilities and the effectiveness of the present method.