Lightweight Multidisciplinary Optimization for Vehicle Part Design

Xiao Chen, Francesco Italiano, Daniel Mainz & Friedrich Wolf-Monheim - Ford Werke GmbH

CHALLENGE - Coming from the Advanced Materials CAE team in Ford’s Research and Innovation Center in Aachen, Germany, this presentation shows the advantages of multidisciplinary optimization to achieve robust, lightweight design at the component level in motor vehicle design.

SOLUTION - The optimization process of a 2-shell stamped design is demonstrated. Objectives are to minimize the assembly weight and cost, ensure all the performances targets are met, and ensure the part feasibility. CAD/CAE software CATIA and modeFRONTIER are coupled in order to find the optimal solution. Simulations are run on HPC (high performance computing).

BENEFITS - In this study, a vehicle chassis part has been optimized achieving a weight reduction of 15% without compromising attribute performance or adding cost with the use of modeFRONTIER multiobjective optimization platform. A highly integrated CAE process chain enables automatic optimization looping, which facilitates the optimization process and makes it more efficient and effective.