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Design Sensitivity Analysis Of Structural Systems

The Fourth Industrial Revolution means the digital transformation of production systems. Cyber-physical systems allow for the horizontal and vertical integration of these production systems as well as the exploitation of the benefits via optimization tools. This article reviews the impact of Industry 4.0 solutions concerning optimization tasks and optimization algorithms, in addition to the identification of the new R&D directions driven by new application options. The basic organizing principle of this overview of the literature is to explore the requirements of optimization tasks, which are needed to perform horizontal and vertical integration. This systematic review presents content from 900 articles on Industry 4.0 and optimization as well as 388 articles on Industry 4.0 and scheduling. It is our hope that this work can serve as a starting point for researchers and developers in the field.

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Industry 4.0-Driven Development of Optimization Algorithms: A Systematic Overview

This article purposes on developing and on re-interpreting the numerical results of a topology optimization for a structural component built via additive manufacturing. A critical appraisal of the ...

Synergy between topology optimization and additive manufacturing in the automotive field

Additive manufacturing adoption in product design: an overview from literature and industry

In the present paper, the use of the topology optimization in a metal Additive Manufacturing application is discussed and applied to an automotive Body-in-White component called dash. The dash is i...

Additive manufacturing and topology optimization: A design strategy for a steering column mounting bracket considering overhang constraints:

Influence of Manufacturing Constraints on the Topology Optimization of an Automotive Dashboard

Optimization methods are useful and effective techniques for the design and development of components from the weight reduction point of view. This paper presents an optimization methodology applied to the front cross-member of a Maserati chassis for metal replacement application with the objective of the minimization of the mass of the structure using composite materials. Firstly, a topological optimization of the front side of the vehicle is performed, and the available design space is considered to determine the optimal load path of the design volume and, consequently, to assess a preliminary geometry of the component under scrutiny. Secondly, free-size optimization of the preliminary cross-member design is developed, initially neglecting and subsequently considering the manufacturing constraints. In addition, a linear analysis of the cross-member, modeled as a rigid component, is carried out to evaluate the maximum contribution of this component on the structural performance of the front side of the vehicle. Finally, size and shuffle optimizations are carried out on the new design concept to determine the number and the thickness of the composite plies, and the optimal stacking sequence, respectively, in order to fulfill the structural requirements. A comparison between the new composite structure and the aluminium Maserati cross-member is presented.

Optimization Methodology for an Automotive Cross-Member in Composite Material

Lightweight design, structural performance and safety requirements represent the reference tasks for the development of innovative cars. For these reasons, both composites and Finite Element (FE) modelling have been widely employed in the last years. This study illustrates a numerical-experimental correlation methodology for Carbon Fibre Reinforcement Plastic (CFRP) laminates employed in a front Maserati hood. At first, an elastic-plastic material law is assessed for orthotropic shells using the Crash Survivability (CRASURV) nonlinear formulation, and a card material is compiled. A wide experimental campaign is performed according to the ASTM standards. Therefore, tensile, compression, shear, inter-laminar shear strength tests and drop weight tests are mandatory for the evaluation of the material properties and its failure modes. Finally, nonlinear forecasts of head impact on the hood are examined, and a preliminary numerical-experimental correlation is presented.

Luca Cavazzoni

Papers

Influence of Manufacturing Constraints on the Topology Optimization of an Automotive Dashboard

Optimization Methodology for an Automotive Cross-Member in Composite Material

Numerical-experimental correlation of composite laminates for automotive applications

Numerical Modeling of Aluminum Alloys Fracture for Automotive Applications