Abstract
An alternative lightweight flatbed trailer design is achieved through a multi-stage optimization procedure. Topology optimization is used to obtain the optimal layout of flatbed trailer frame beams that provide minimum compliance when subjected to bending loads and exhibits maximum torsional natural frequency. The ground structure approach is used to define the trailer frame layout by generating numerous beams connected to predefined points in the trailer. Topology optimization is formulated as a multi-objective problem subject to a mass constraint. Responses and sensitivities are evaluated using ANSYS, and the optimization problem is solved using the moving asymptotes method. The thicknesses, widths, and heights of the C-channel beams are optimized for further weight reduction while at least maintaining the structural performances of the original design. Size and shape optimizations are performed using OptiStruct. The new optimal design is approximately 13% (275 kg) lighter than and as stiff as the original design for bending loads. However, the former has 3.5 times higher torsional natural frequency than the latter. Moreover, the new optimal design has positive manufacturability because the channel beams will be made out of commercially available sheet metals. The same fabrication technology as for a conventional flatbed trailer is possibly to be used.
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