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A metamodel-based multidisciplinary design optimization process for automotive structures
Linköping University, Department of Management and Engineering, Solid Mechanics. Linköping University, Faculty of Science & Engineering. Combitech AB,Trollhättan, Sweden.
Linköping University, Department of Management and Engineering, Solid Mechanics. Linköping University, The Institute of Technology.
Linköping University, Department of Management and Engineering, Solid Mechanics. Linköping University, The Institute of Technology.
2015 (English)In: Engineering with Computers, ISSN 0177-0667, E-ISSN 1435-5663, Vol. 31, no 4, 711-728 p.Article in journal (Refereed) Published
Abstract [en]

Automotive companies continuously strive to design better products faster and more cheaply using simulation models to evaluate every possible aspect of the product. Multidisciplinary design optimization (MDO) can be used to find the best possible design taking into account several disciplines simultaneously, but it is not yet fully integrated within automotive product development. The challenge is to find methods that fit company organizations and that can be effectively integrated into the product development process. Based on the characteristics of typical automotive structural MDO problems, a metamodel-based MDO process intended for large-scale applications with computationally expensive simulation models is presented and demonstrated in an example. The process is flexible and can easily fit into existing organizations and product development processes where different groups work in parallel. The method is proven to be efficient for the discussed example and improved designs can also be obtained for more complex industrial cases with comparable characteristics.

Place, publisher, year, edition, pages
Springer, 2015. Vol. 31, no 4, 711-728 p.
Keyword [en]
Multidisciplinary design optimization (MDO); metamodel-based design optimization (MBDO); automotive structures
National Category
Engineering and Technology
Identifiers
URN: urn:nbn:se:liu:diva-88135DOI: 10.1007/s00366-014-0381-yISI: 000360859000004OAI: oai:DiVA.org:liu-88135DiVA: diva2:601780
Available from: 2013-01-30 Created: 2013-01-30 Last updated: 2017-12-06Bibliographically approved
In thesis
1. Metamodel-Based Multidisciplinary Design Optimization of Automotive Structures
Open this publication in new window or tab >>Metamodel-Based Multidisciplinary Design Optimization of Automotive Structures
2017 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Multidisciplinary design optimization (MDO) can be used in computer aided engineering (CAE) to efficiently improve and balance performance of automotive structures. However, large-scale MDO is not yet generally integrated within automotive product development due to several challenges, of which excessive computing times is the most important one. In this thesis, a metamodel-based MDO process that fits normal company organizations and CAE-based development processes is presented. The introduction of global metamodels offers means to increase computational efficiency and distribute work without implementing complicated multi-level MDO methods.

The presented MDO process is proven to be efficient for thickness optimization studies with the objective to minimize mass. It can also be used for spot weld optimization if the models are prepared correctly. A comparison of different methods reveals that topology optimization, which requires less model preparation and computational effort, is an alternative if load cases involving simulations of linear systems are judged to be of major importance.

A technical challenge when performing metamodel-based design optimization is lack of accuracy for metamodels representing complex responses including discontinuities, which are common in for example crashworthiness applications. The decision boundary from a support vector machine (SVM) can be used to identify the border between different types of deformation behaviour. In this thesis, this information is used to improve the accuracy of feedforward neural network metamodels. Three different approaches are tested; to split the design space and fit separate metamodels for the different regions, to add estimated guiding samples to the fitting set along the boundary before a global metamodel is fitted, and to use a special SVM-based sequential sampling method. Substantial improvements in accuracy are observed, and it is found that implementing SVM-based sequential sampling and estimated guiding samples can result in successful optimization studies for cases where more conventional methods fail.

Place, publisher, year, edition, pages
Linköping, Sweden: Linköping University Electronic Press, 2017. 48 p.
Series
Linköping Studies in Science and Technology. Dissertations, ISSN 0345-7524 ; 1870
Keyword
multidisciplinary design optimization (MDO), metamodel, artificial neural network (ANN), support vector machine (SVM), sequential sampling, crashworthiness, automotive structure, spot weld optimization
National Category
Mechanical Engineering Applied Mechanics Vehicle Engineering
Identifiers
urn:nbn:se:liu:diva-140875 (URN)10.3384/diss.diva-140875 (DOI)9789176854822 (ISBN)
Public defence
2017-10-03, C3, Hus C, Campus Valla, Linköping, 10:15 (English)
Opponent
Supervisors
Funder
VINNOVA, 2009-00314VINNOVA, 2014-01340
Available from: 2017-09-14 Created: 2017-09-14 Last updated: 2017-09-20Bibliographically approved
2. Multidisciplinary Design Optimization of Automotive Structures
Open this publication in new window or tab >>Multidisciplinary Design Optimization of Automotive Structures
2013 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Multidisciplinary design optimization (MDO) can be used as an effective tool to improve the design of automotive structures. Large-scale MDO problems typically involve several groups who must work concurrently and autonomously for reasons of efficiency. When performing MDO, a large number of designs need to be rated. Detailed simulation models used to assess automotive design proposals are often computationally expensive to evaluate. A useful MDO process must distribute work to the groups involved and be computationally efficient.

In this thesis, MDO methods are assessed in relation to the characteristics of automotive structural applications. Single-level optimization methods have a single optimizer, while multi-level optimization methods have a distributed optimization process. Collaborative optimization and analytical target cascading are possible choices of multi-level optimization methods for automotive structures. They distribute the design process, but are complex. One approach to handle the computationally demanding simulation models involves metamodel-based design optimization (MBDO), where metamodels are used as approximations of the detailed models during optimization studies. Metamodels can be created by individual groups prior to the optimization process, and therefore also offer a way of distributing work. A single-level optimization method in combination with metamodels is concluded to be the most straightforward way of implementing MDO into the development of automotive structures.

Place, publisher, year, edition, pages
Linköping: Linköping University Electronic Press, 2013. 60 p.
Series
Linköping Studies in Science and Technology. Thesis, ISSN 0280-7971 ; 1578
Keyword
Multidisciplinary design optimization (MDO); single-level optimization methods; multi-level optimization methods; metamodel-based design optimization (MBDO); automotive structures
National Category
Engineering and Technology
Identifiers
urn:nbn:se:liu:diva-89136 (URN)LIU-TEK-LIC-2013:12 (Local ID)978-91-7519-688-6 (ISBN)LIU-TEK-LIC-2013:12 (Archive number)LIU-TEK-LIC-2013:12 (OAI)
Presentation
2013-03-08, A32, Hus A, Campus Valla, Linköpings universitet, Linköping, 10:15 (Swedish)
Opponent
Supervisors
Available from: 2013-02-22 Created: 2013-02-22 Last updated: 2017-09-14Bibliographically approved
3. Metamodel-Based Design Optimization: A Multidisciplinary Approach for Automotive Structures
Open this publication in new window or tab >>Metamodel-Based Design Optimization: A Multidisciplinary Approach for Automotive Structures
2013 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Automotive companies are exposed to tough competition and therefore strive to design better products in a cheaper and faster manner. This challenge requires continuous improvements of methods and tools, and simulation models are therefore used to evaluate every possible aspect of the product. Optimization has become increasingly popular, but its full potential is not yet utilized. The increased demand for accurate simulation results has led to detailed simulation models that often are computationally expensive to evaluate. Metamodel-based design optimization (MBDO) is an attractive approach to relieve the computational burden during optimization studies. Metamodels are approximations of the detailed simulation models that take little time to evaluate and they are therefore especially attractive when many evaluations are needed, as e.g. in multidisciplinary design optimization (MDO).

In this thesis, state-of-the-art methods for metamodel-based design optimization are covered and different multidisciplinary design optimization methods are presented. An efficient MDO process for large-scale automotive structural applications is developed where aspects related to its implementation is considered. The process is described and demonstrated in a simple application example. It is found that the process is efficient, flexible, and suitable for common structural MDO applications within the automotive industry. Furthermore, it fits easily into an existing organization and product development process and improved designs can be obtained even when using metamodels with limited accuracy. It is therefore concluded that by incorporating the described metamodel-based MDO process into the product development, there is a potential for designing better products in a shorter time.

Place, publisher, year, edition, pages
Linköping: Linköping University Electronic Press, 2013. 78 p.
Series
Linköping Studies in Science and Technology. Thesis, ISSN 0280-7971 ; 1565
Keyword
Metamodel-based design optimization (MBDO); multidisciplinary design optimization (MDO); automotive structures
National Category
Engineering and Technology
Identifiers
urn:nbn:se:liu:diva-88136 (URN)LIU-TEK-LIC-2013:1 (Local ID)978-91-7519-721-0 (ISBN)LIU-TEK-LIC-2013:1 (Archive number)LIU-TEK-LIC-2013:1 (OAI)
Presentation
2013-01-25, A36, Hus A, ingång 15 plan 3, Campus Valla, Linköpings universitet, Linköping, 10:15 (Swedish)
Opponent
Supervisors
Available from: 2013-01-30 Created: 2013-01-30 Last updated: 2017-09-14Bibliographically approved

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Ryberg, Ann-BrittDomeij Bäckryd, RebeckaNilsson, Larsgunnar

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