Abstract
In rubber bumper design one of the most important technical properties of the product is the force-displacement curve under a compression load, which is a highly nonlinear behavior because of the large deformation, the rubber material and the contacts. Finite element analysis is a good way to evaluate the working characteristics of the rubber part. Fulfillment of customer needs requires a general iterative design method where the objective can be reached with the modification of the product shape. The determination of the optimum requires numerous iterations of finite element analysis which is computationally expensive. With the integration of the Response Surface Method (RSM) into the design process of a two-variable shape optimization task, the optimal design can be achieved more efficiently. Four different Design of Experiments (DOE) methods were used to intelligently chose design points. As a metamodeling technique, Genetic Aggregation was selected to predict the relation between the sampled geometric variables and the nonlinear objective function value. The Nonlinear Programming by Quadratic Lagrangian (NLPQL) and the Mixed-Integer Sequential Quadratic Programming (MISQP) algorithms with different settings were tested to find the optimum of the response surface. As a result, the most accurate and efficient DOE method and optimization algorithm were determined. The introduced Response Surface Method-based optimization is proved to be suitable to determine the shape of the rubber jounce bumper, which meets the technical requirements.
Highlights
Rubber bumpers built into air spring structures perform several critical tasks, such as working together with the air spring as a secondary spring, modifying the original characteristics of the air spring when pressed together
3.3 Response surface fitted to the Maximin Latin Hypercube Design (LHD) The number of sampling in the current investigation is identical with the number of design points sampled by Central Composite Design (CCD) to be suitable for comparison
Foremost the axisymmetric finite element model for the two-dimensional shape optimization of automotive rubber jounce bumper was built with the use of calibrated two-term Mooney-Rivlin material model
Summary
Rubber bumpers built into air spring structures perform several critical tasks, such as working together with the air spring as a secondary spring, modifying the original characteristics of the air spring when pressed together The product investigated is applied in the air springs of lorries, where the force-displacement characteristic for the compression load is one of the most challenging technical requirements In several cases, this is enforced by customer requirements, which leads to the iterative design process. If there is an opportunity to parameterize the process from creating a geometry to obtaining the results, conversion meeting technical requirements can be automated In this case, numerous design optimization techniques can be used, which shortens design time and reduces engineering work
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