The Product Innovative Design Methodology Integrating Reverse Engineering with Optimization - A Case Study on Automotive Styling

H.W. Xiong, J. Xu, C.X. Xu, M. Pan (Guangdong University of Technology)

CHALLENGE - In the initial design phase of a car body, it is challenging to meet both aesthetic and performance requirements simultaneously. In this paper, an innovative design methodology integrating reverse engineering (RE) with optimization methodology is presented. 

SOLUTION - The proposed methodology consists of three main modules: RE module, Free Form Deformation (FFD) module and CAE-based optimization module. A commercial software ImageWare is used in RE module to reconstruct the CAD model from the measured data. Two important performance parameters are taken as objectives: the minimization of lift and drag coefficient. Response surface methodology (RSM) is used to optimize the initial digital model. A design of experiments (DOE) table is generated by Sobol sequence method and the response function is approximated through the Kriging algorithm. All procedures are integrated within optimization software modeFRONTIER









BENEFITS -  Multiple response variables create a challenge because what is optimal for one response may not be optimal for other responses, therefore modeFRONTIER's multiobjective genetic algorithm is adopted. The final optimized result is shown above. In this test, the initial styling intent is captured by the RE module, and the aerodynamic performance is improved by following the optimization module, maintaining the aesthetic aspect simultaneously.