Topometry Optimization of Energy Absorbing Structure through Targeting Force-Displacement Method considering Tailor Rolled Blank Process

Abstract

Inspired by topometry optimization, this work proposed a new design approach that mixed of targeting force-displacement (TFD) method and tailor rolled blank (TRB) process for thin-walled energy absorption structures, which has vast applied prospects in the aerospace and automotive industries. This method not only overcomes manufacturing difficulty caused by the TFD method based on topometry optimization but also provides a new idea for TRB energy absorption structure. The optimized results can be transferred to the computer aided design environment without additional postprocessing. Firstly, a uniform thickness constraint is introduced to make the designed structure have constant thickness distribution along desired direction; topometry optimization is carried out to use TFD method. Secondly, a method that can automatically divide the design domain is developed. The adjacent elements with smaller thickness differences are merged to form TRB subdomains based on the optimization results of forestep, and the TFD method is used again. Finally, TRB finite element modeling codes is developed. According to the second step, modeling of the transition zone is added to finally form the TRB structure that meets the requirements of manufacturing. This method is used to optimize the crashworthiness of the thin-walled tube under axial and oblique loading. Numerical results demonstrate the effectiveness of this method. Therefore, this method can be used to design high-efficiency energy absorber on aircraft or automobile, such as the strut of aircraft and energy absorption box of automobile.