A Novel Compliance Constrained Mass Optimization Framework for Vehicle Suspension Subframe Structures

Chen, Liang; Shen, Herman; Xin, Zhang; Gao, Jianghua

doi:10.4271/10-04-02-0008

Cited by 7 publications

(1 citation statement)

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“…This action is obviously supporting the movement on the reduction of carbon footprint issues (Hoffmann, Haag, & Müssig, 2021). There are many methods to have a lighter component yet maintain still its mechanical property benefits, such as the use of lightweight material (Gonçalves, Monteiro, & Iten, 2022), forming methodology (Rosenthal et al, 2020), and mass optimization (Chen, Shen, Zhang, & Gao, 2020). Additionally, the other issues in reducing the overall mass of the component are related to the manufacturing process of the component (Zhu et al, 2021).…”

Section: Introductionmentioning

confidence: 87%

Lightweight Design and Finite Element Analysis of Brake Lever for Motorcycle Application

Puji Prasetyono,

Yudianto,

Adiyasa

2023

ComTech

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A lightweight component design contributes to the overall optimization of a system to be more effective and efficient. Then, it can lead to the contribution of a carbon footprint reduction. The research aimed to propose a novel lightweight brake lever design for motorcycle applications and numerically investigate its performance by comparing the proposed design with different utilized materials. The subject of the research was an optimized brake lever for motorcycle application. The materials used were aluminum alloy, structural steel, and titanium alloy. A Finite Element Method (FEM) analysis was employed to investigate the proposed brake lever design. Three proposed designs were introduced with the mass reduction in each optimization up to 50,9% of reduced mass. Maximum stress was observed on the most optimized design with a value of 297 MPa. The strain and total deformation were also investigated among the components. In the result, the stress-strain graph shows that the most optimized brake lever experiences the highest stress with the highest strain value. Furthermore, the highest safety factor is achieved with the utilization of titanium alloy, reaching the value of 6,28 for preliminary design and 3,1 for the most optimized component. However, the lightest component can be obtained using aluminum alloy.

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Section: Introductionmentioning

confidence: 87%

Lightweight Design and Finite Element Analysis of Brake Lever for Motorcycle Application

Puji Prasetyono,

Yudianto,

Adiyasa

2023

ComTech

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A Design Optimization Process of Improving the Automotive Subframe Dynamic Stiffness Using Tuned Rubber Mass Damper

Gao,

Zhang,

2024

Vehicle Dynamics, Stability, and NVH

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<div>Automotive subframe is a critical chassis component as it connects with the suspension, drive units, and vehicle body. All the vibration from the uneven road profile and drive units are passed through the subframe to the vehicle body. OEMs usually have specific component-level drive point dynamic stiffness (DPDS) requirements for subframe suppliers to achieve their full vehicle NVH goals. Traditionally, the DPDS improvement for subframes welded with multiple stamping pieces is done by thickness and shape optimization. The thickness optimization usually ends up with a huge mass penalty since the stamping panel thickness has to be changed uniformly not locally. Structure shape and section changes normally only work for small improvements due to the layout limitations. Tuned rubber mass damper (TRMD) has been widely used in the automotive industry to improve the vehicle NVH performance thanks to the minimum mass it adds to the original structure. Therefore, this article establishes a design optimization process utilizing the TRMD to improve the vehicle subframes DPDS more efficiently. First, the subframe critical normal modes for the DPDS issue are identified through modal participation factor analysis with the finite element (FE) model of the subframe. A lumped mass–stiffness–damper mathematical model is established by the TRMD and the identified critical modes. The parameter correlation analysis is conducted through the simple math model. Thereafter, parameter tuning is done based on the DOE study with an integrated FE model composed of the subframe and the TRMD. Furthermore, a rubber steel-type TRMD is built and verified virtually for demonstration. The proposed framework could solve the component-level DPDS problems efficiently with minimum mass and cost penalty compared to traditional methods. And it could be introduced into the subframe early design stage to ensure a lightweight final design, which meets all the component-level DPDS requirements.</div>

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Comparison of Rubber Bushing Models for Loads Analysis

Yang

Zhang

2021

SAE Technical Paper Series

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A Novel Compliance Constrained Mass Optimization Framework for Vehicle Suspension Subframe Structures

Cited by 7 publications

References 0 publications

Lightweight Design and Finite Element Analysis of Brake Lever for Motorcycle Application

Lightweight Design and Finite Element Analysis of Brake Lever for Motorcycle Application

A Design Optimization Process of Improving the Automotive Subframe Dynamic Stiffness Using Tuned Rubber Mass Damper

Comparison of Rubber Bushing Models for Loads Analysis

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