Problems of finding the best solutions to ensure the passive safety of the cabins of trucks at a minimum weight

Abstract

This paper considered the main problems of finding the optimal parameters of a truck cabin based on parametric and topological optimization in order to meet the requirements for passive safety according to international rules and obtain its minimum mass. The article presents the developed rational finite element models (FEM) of the cabin and the pendulum for optimization problems, allowing to obtain results with acceptable accuracy and minimal solution time when using the LS-OPT and LS-TaSC programs with the LS-DYNA solver. Steel lining and foam aluminum filler are used as cabin reinforcement elements. To solve the problem and more fully assess the effect of the parameters, several options for cabin refinement were considered. Topological optimization was carried out with the aim of obtaining a picture of the best distribution of the filler along the cabin frame. Parametric optimization was carried out by selection of the properties of the filler (aluminum foam) and the thickness of the structural elements of the cabin. In addition to optimization, the sensitivity of the design to the variation of variable parameters was investigated in order to identify the degree of influence on the optimization result. Since the duration of the solution is very high (up to several days on available computers), an approach was developed based on the studies that were carried out, which at various stages reduced the number of variables and, thus, reduced the solution time. As a result, it was ensured that the requirements for passive safety were satisfied (these requirements were not met before optimization) with optimal mass distribution as a result of the combined use of linings and filler. The increase in cabin weight was 20%. The use of linings only allowed to meet the rules for passive safety, but gave an even greater increase in the weight of the cabin.