基于代理模型的车身吸能结构抗撞性优化
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摘要
作为一个在汽车领域的“发展中国家”，我国许多整车厂家很大程度上缺乏完全自主研发的能力。但随着自主知识产权意识的不断加强，广大车企对自主研发的需求逐步增加。对于这一现状，政府出台了一系列针对汽车产业的调整规划，特别是对自主品牌、自主创新的支持力度非常巨大，这也激发了民族汽车产业的迅猛发展。国家“十二五”发展规划中提出了“建设原理创新、产品创新和产业化创新体系。推广结构轻量化、整车优化、推动汽车产品节能”的汽车产业的重点发展方向。“汽车可靠耐久、安全、节能减排关键技术”与“汽车轻量化技术与工艺材料应用开发”等汽车关键核心技术也被作为重大专项进行科技攻关。
基于以上原因，要想真正发展我国自己的汽车工业品牌，提高国际竞争力，整车的安全性是急需提高的一项内容，而抗撞性又是车辆安全中的关键一环。传统的车身设计流程由于存在耗费周期长，CAE分析不能有效地为前期设计进行指导等问题。因此，在进行设计及试验之前，提供一个比较完整充分的碰撞仿真分析作为参考是十分有必要的。然而针对车辆碰撞这类非线性程度较高、结构自由度巨大的问题，反复的计算和修改将耗费大量的财力和人力。因此对于这类问题，通过试验设计构建代理模型的方法可有效地减少计算时间，进一步的方便抗撞性优化设计，有效地提高车身设计的效率，并满足整车的安全性需求。另外针对详细有限元模型构建等效的简化模型也是有效规避计算量的方法。简化车身部件的基本单元是由梁、板、接头构成的，其中不同截面的梁占很大成分，因此应通过对不同类型薄壁梁的几何及力学特性的基础理论分析，考虑车身结构几何特性、力学特性及工艺因素，对轿车碰撞参数化结构的建模方式进行研究，分别建立轿车车身部件的有限元模型及其相应的参数化简化模型，为轿车参数化结构建模及优化奠定基础。
本文依托2009年国家自然科学基金项目，2009年及2012年吉林省科技发展计划重大专项的资助，以及课题组与中国第一汽车集团技术中心车身部多年来的合作，使用自主开发的简化车身框架结构参数的快速优化专用系统平台，建立原结构参数化模型及相应的代理模型，以轻量化、高吸能性为目标，实现车身产品在概念设计阶段的快速参数化建模及基于代理模型的车身主要吸能部件的抗撞性优化设计，有效提高模型修改及优化的效率。主要工作包括：
（1）碰撞安全性仿真理论及抗撞性优化方法。
详细介绍了汽车碰撞安全性仿真理论，针对非线性有限元法的适用条件进行探讨，给出了相关的运动方程、守恒方程和边界条件等公式的推导过程，以及单元计算的单点高斯积分方法和沙漏现象。此外，重点针对本文所研究的基于代理模型的抗撞性优化方法进行研究，介绍了试验设计的两种常用方法和几种代理模型的构建原理，并对不同构建代理模型方法的适用范围进行了对比分析。最后，概述了粒子群优化算法的基本原理和求解流程。
（2）正碰工况下基于代理模型的吸能盒结构抗撞性优化设计。
以车身前部抗撞部件吸能盒结构的常见类型：方形截面薄壁锥管为研究对象，在低速冲击工况下研究其具有最佳抗撞性能的优化设计方案。将压溃力效率及比吸能作为评价指标，建立加权组合形式的多目标优化模型。分析并探讨分布设置诱导槽对结构吸能与压溃力的影响，选择诱导槽设定的可行区域。以槽的个数、非均匀分布的槽间距离及槽的深度等作为优化参数。在根据试验设计方法合理选取样本点后，分别应用三次多项式响应面法及径向基法构建其有效代理模型，并采用粒子群法进行优化设计，得出使结构最优的诱导槽位置分布及数量，并与对应参数的圆形截面锥管的抗撞性进行比较，发现正方形截面的抗撞性更好。通过仿真分析验证该方法的有效性。研究结果证明，这种科学合理施加诱导槽的方式可有效提高结构的抗撞性能，为吸能盒结构设计提供参考。
（3）侧碰工况下基于代理模型的车门结构的抗撞性优化。
对某款轿车车门的有限元模型进行了侧碰的仿真模拟，通过能量、碰撞接触力、变形位移及加速度的曲线分析其碰撞安全性。随后，基于均匀试验设计方法结合多项式响应面法，构建了该车门结构在特定工况下的吸能量、最大碰撞力和总质量关于板厚参数的代理模型，采用粒子群算法对响应面模型进行优化设计。在对原结构质量和最大碰撞力分别进行约束的情况下，给出车门主要部件厚度的优化设计方案，从而有效提升车门结构的吸能值，最大程度改善了整车的抗撞性能。
（4）六边形截面、槽型截面混合截面薄壁梁结构的弯曲特性分析及B柱结构简化模型的建立。
通过对六边形截面及槽形截面薄壁梁的弯曲特性的研究，基于能量守恒定律，推导了六边形截面和槽型截面薄壁梁通过各条塑性铰线耗散能量的计算表达式，得到它们的弯矩与转角关系，即M (θ)-θ曲线。由此可以基于LS-DYNA软件快速定义非线性转动弹簧相关属性，并将这种零尺寸的非线性转动弹簧放置于B柱弯曲时产生塑性铰的区域。这样便建立了由非线性刚梁和转动弹簧所构成的B柱简化模型。通过对详细模型与简化模型的变形效果、位移曲线和能量曲线的比较，验证了简化模型的有效性。同时为整车模型的简化及提高其抗撞性优化效率奠定了基础。
As a developing country in vehicle domain, most of vehicle manufacturers are lack ofthe ability for independent research. However, with the gradual enhancement of the awarenessfor independent intellectual property rights, many vehicle companies pay attention to theindependent research and development. Hence, especially for the independent brands, thegovernment publishes series of programming, which improves the fast development ofnational vehicle industries. The innovation of construction principle, product innovation andindustrial innovation system were put forward in the national ‘12th Five Year Plan’.Consequently, structure lightweight, vehicle optimization and energy-saving for vehicleproducts have been focused on as a key development for vehicle industry. Moreover, not onlythe main technologies for reliability, safety and energy conservation, but also the developmentfor lightweight and materials application have been researched as major projects in thedomain of vehicle.
For the reasons above, improving vehicle safety, especially the crashworthiness, is one ofthe urgent work, which will develop our own brand of automobile manufacturer and improveinternational competitiveness. The traditional procedure of carbody design requires long cycleand may not be effective guidance for preliminary design. Hence, it is necessary to take arelatively complete crash simulation analysis as a reference. However, vehicle collisionproblem, which is high nonlinear and contains huge degrees of freedom, will spend a lot offinancial resources and computation. In order to solve the problem, constructing surrogatemodels based on DOE method can effectively reduce the computation time, facilitate thecrashworthiness optimization design, and improve the efficiency of the carbody design, whichwill satisfy the security requirement of the vehicle. Moreover, computation of the simplified model equivalent to the detail FE model is less. The basic units of the simplified carbodycomponents are composed by beams, plates and joints. Especially, beams with differentsections take large proportions.
Based on not only the analysis of geometrical properties and mechanical properties fordifferent types of thin-walled beams, but also the geometrical properties, mechanicalproperties and production process, this paper researches on the method of constructingparameterized structure for vehicle collision, and then establishes the FE models andcorresponding simplified models of the car body parts, which are the foundation forparametric modeling and optimization.
This paper is supported by the National Natural Science Foundation of China, Scienceand Technology Development Plan of Jilin province in2009and2012, and the corporationwith body department of China Faw Group Corporation R&D Center. According to thespecial optimization platform for simplified vehicle frame structures which compliedindependently, fast parametric modeling and crashworthiness optimization for the mainenergy-absorbing components of vehicle based on surrogate models have been studied, whichare all considered for the concept design. During the process of optimization, both thelightweight and high energy conservation are taken as optimization objects. This may greatlyenhance the effectiveness of structure modification and optimization. The main work can beconcluded as follows.
(1) Theories of crash safety simulation and crashworthiness optimization methods.
Theories of vehicle crash safety simulation are introduced in detail, such as discussionsabout the application conditions for non-linear FE method, derivations of motion equations,conservation equations and boundary conditions. Also, the Gaussian integration method basedon a single point for unit calculation and the hourglass phenomenon are illustrated. Moreover,methods for crashworthiness optimization based on surrogate models are focused on. Afterillustrating several methods for DOE and the construction of surrogate models, this paperanalyzes their application ranges. Finally, both the basic principles and solving process of theparticle swarm optimization method are summarized.
(2) Crashworthiness optimization of crash box structure based on its surrogatemodel during front collision.
The crashworthiness optimization with low velocity impact, according to thin-walledtaper tube with square cross section, which often appears as an energy absorbing part of crashbox, has been researched. A multi-objective optimization problem based on a combination ofCFE and SEA, has been put forward. Grooves are induced in the original structure. Afteranalyzed the relationship between energy absorption and crash force of structure withinducing grooves, the feasible design area of inducing grooves is obtained. The number,non-uniform intervals and depth of inducing grooves are taken as optimal parameters. Afterchosen sampling points reasonably, surrogate models are constructed by cubic polynomialsresponse surface method and radial basis function method respectively. Then the optimalnumber and distribution of inducing grooves are obtained by PSO method. FE analysisvalidates the effectiveness of this method. Results prove that compared with the structurewithout inducing groove, crashworthiness of the structure added inducing groovesscientifically is improved efficiently, which can be useful during the design of crash box.
(3) Crashworthiness optimization of car door structure based on its surrogatemodel during side collision.
Simulation for FE model of a certain car door structure during side collision has beenresearched. The curves of energy, collision contact force, deformation displacement andacceleration has been employed for analyzing the crashworthiness safety. Then, based on theuniform design and polynomial response surface method, surrogate models of the energy,maximum collision force and total mass of the car door structure under a special condition areconstructed respectively, as well as the thickness of planes are taken as variables. PSO methodis used as a tool for optimization of the surrogate models. As well as the mass and maximumcollision force of the original structure are treated as constraint conditions, the optimal designfor the main parts thickness of car door structure has been determined finally. With the design,one can effectively increase the energy of car door structure and improve the crashworthinessof the whole car.
(4) Analysis about the bending behavior of thin-walled beams with hexagonal andchannel sections and construction for simplified model of B pillar.
According to the researches on bending behavior of thin-walled beams with hexagonaland channel sections and the law for conservation of energy, formulas for calculating thedissipated energy of thin-walled beams through each plastic hinge line. The curve ofrelationship between the moment and rotation (i.e. M(θ)-θ) has been obtained. So therelative properties of non-linear rotation springs can be defined quickly by LS-DYNA. Bysetting the non-linear rotation springs into the zone appearing plastic hinges which are causedby the bending of B pillar, one can construct the simplified model of B pillar by non-linearbeams and rotation springs. After comparing the deformation effect, displacement curve andenergy curve of simplified model with those of detailed model, the effectiveness of simplifiedmodel is verified. The work is benefit to the construction for simplified model of vehicle andimprovement of effectiveness for crashworthiness optimization.
基于以上原因，要想真正发展我国自己的汽车工业品牌，提高国际竞争力，整车的安全性是急需提高的一项内容，而抗撞性又是车辆安全中的关键一环。传统的车身设计流程由于存在耗费周期长，CAE分析不能有效地为前期设计进行指导等问题。因此，在进行设计及试验之前，提供一个比较完整充分的碰撞仿真分析作为参考是十分有必要的。然而针对车辆碰撞这类非线性程度较高、结构自由度巨大的问题，反复的计算和修改将耗费大量的财力和人力。因此对于这类问题，通过试验设计构建代理模型的方法可有效地减少计算时间，进一步的方便抗撞性优化设计，有效地提高车身设计的效率，并满足整车的安全性需求。另外针对详细有限元模型构建等效的简化模型也是有效规避计算量的方法。简化车身部件的基本单元是由梁、板、接头构成的，其中不同截面的梁占很大成分，因此应通过对不同类型薄壁梁的几何及力学特性的基础理论分析，考虑车身结构几何特性、力学特性及工艺因素，对轿车碰撞参数化结构的建模方式进行研究，分别建立轿车车身部件的有限元模型及其相应的参数化简化模型，为轿车参数化结构建模及优化奠定基础。
本文依托2009年国家自然科学基金项目，2009年及2012年吉林省科技发展计划重大专项的资助，以及课题组与中国第一汽车集团技术中心车身部多年来的合作，使用自主开发的简化车身框架结构参数的快速优化专用系统平台，建立原结构参数化模型及相应的代理模型，以轻量化、高吸能性为目标，实现车身产品在概念设计阶段的快速参数化建模及基于代理模型的车身主要吸能部件的抗撞性优化设计，有效提高模型修改及优化的效率。主要工作包括：
（1）碰撞安全性仿真理论及抗撞性优化方法。
详细介绍了汽车碰撞安全性仿真理论，针对非线性有限元法的适用条件进行探讨，给出了相关的运动方程、守恒方程和边界条件等公式的推导过程，以及单元计算的单点高斯积分方法和沙漏现象。此外，重点针对本文所研究的基于代理模型的抗撞性优化方法进行研究，介绍了试验设计的两种常用方法和几种代理模型的构建原理，并对不同构建代理模型方法的适用范围进行了对比分析。最后，概述了粒子群优化算法的基本原理和求解流程。
（2）正碰工况下基于代理模型的吸能盒结构抗撞性优化设计。
以车身前部抗撞部件吸能盒结构的常见类型：方形截面薄壁锥管为研究对象，在低速冲击工况下研究其具有最佳抗撞性能的优化设计方案。将压溃力效率及比吸能作为评价指标，建立加权组合形式的多目标优化模型。分析并探讨分布设置诱导槽对结构吸能与压溃力的影响，选择诱导槽设定的可行区域。以槽的个数、非均匀分布的槽间距离及槽的深度等作为优化参数。在根据试验设计方法合理选取样本点后，分别应用三次多项式响应面法及径向基法构建其有效代理模型，并采用粒子群法进行优化设计，得出使结构最优的诱导槽位置分布及数量，并与对应参数的圆形截面锥管的抗撞性进行比较，发现正方形截面的抗撞性更好。通过仿真分析验证该方法的有效性。研究结果证明，这种科学合理施加诱导槽的方式可有效提高结构的抗撞性能，为吸能盒结构设计提供参考。
（3）侧碰工况下基于代理模型的车门结构的抗撞性优化。
对某款轿车车门的有限元模型进行了侧碰的仿真模拟，通过能量、碰撞接触力、变形位移及加速度的曲线分析其碰撞安全性。随后，基于均匀试验设计方法结合多项式响应面法，构建了该车门结构在特定工况下的吸能量、最大碰撞力和总质量关于板厚参数的代理模型，采用粒子群算法对响应面模型进行优化设计。在对原结构质量和最大碰撞力分别进行约束的情况下，给出车门主要部件厚度的优化设计方案，从而有效提升车门结构的吸能值，最大程度改善了整车的抗撞性能。
（4）六边形截面、槽型截面混合截面薄壁梁结构的弯曲特性分析及B柱结构简化模型的建立。
通过对六边形截面及槽形截面薄壁梁的弯曲特性的研究，基于能量守恒定律，推导了六边形截面和槽型截面薄壁梁通过各条塑性铰线耗散能量的计算表达式，得到它们的弯矩与转角关系，即M (θ)-θ曲线。由此可以基于LS-DYNA软件快速定义非线性转动弹簧相关属性，并将这种零尺寸的非线性转动弹簧放置于B柱弯曲时产生塑性铰的区域。这样便建立了由非线性刚梁和转动弹簧所构成的B柱简化模型。通过对详细模型与简化模型的变形效果、位移曲线和能量曲线的比较，验证了简化模型的有效性。同时为整车模型的简化及提高其抗撞性优化效率奠定了基础。
As a developing country in vehicle domain, most of vehicle manufacturers are lack ofthe ability for independent research. However, with the gradual enhancement of the awarenessfor independent intellectual property rights, many vehicle companies pay attention to theindependent research and development. Hence, especially for the independent brands, thegovernment publishes series of programming, which improves the fast development ofnational vehicle industries. The innovation of construction principle, product innovation andindustrial innovation system were put forward in the national ‘12th Five Year Plan’.Consequently, structure lightweight, vehicle optimization and energy-saving for vehicleproducts have been focused on as a key development for vehicle industry. Moreover, not onlythe main technologies for reliability, safety and energy conservation, but also the developmentfor lightweight and materials application have been researched as major projects in thedomain of vehicle.
For the reasons above, improving vehicle safety, especially the crashworthiness, is one ofthe urgent work, which will develop our own brand of automobile manufacturer and improveinternational competitiveness. The traditional procedure of carbody design requires long cycleand may not be effective guidance for preliminary design. Hence, it is necessary to take arelatively complete crash simulation analysis as a reference. However, vehicle collisionproblem, which is high nonlinear and contains huge degrees of freedom, will spend a lot offinancial resources and computation. In order to solve the problem, constructing surrogatemodels based on DOE method can effectively reduce the computation time, facilitate thecrashworthiness optimization design, and improve the efficiency of the carbody design, whichwill satisfy the security requirement of the vehicle. Moreover, computation of the simplified model equivalent to the detail FE model is less. The basic units of the simplified carbodycomponents are composed by beams, plates and joints. Especially, beams with differentsections take large proportions.
Based on not only the analysis of geometrical properties and mechanical properties fordifferent types of thin-walled beams, but also the geometrical properties, mechanicalproperties and production process, this paper researches on the method of constructingparameterized structure for vehicle collision, and then establishes the FE models andcorresponding simplified models of the car body parts, which are the foundation forparametric modeling and optimization.
This paper is supported by the National Natural Science Foundation of China, Scienceand Technology Development Plan of Jilin province in2009and2012, and the corporationwith body department of China Faw Group Corporation R&D Center. According to thespecial optimization platform for simplified vehicle frame structures which compliedindependently, fast parametric modeling and crashworthiness optimization for the mainenergy-absorbing components of vehicle based on surrogate models have been studied, whichare all considered for the concept design. During the process of optimization, both thelightweight and high energy conservation are taken as optimization objects. This may greatlyenhance the effectiveness of structure modification and optimization. The main work can beconcluded as follows.
(1) Theories of crash safety simulation and crashworthiness optimization methods.
Theories of vehicle crash safety simulation are introduced in detail, such as discussionsabout the application conditions for non-linear FE method, derivations of motion equations,conservation equations and boundary conditions. Also, the Gaussian integration method basedon a single point for unit calculation and the hourglass phenomenon are illustrated. Moreover,methods for crashworthiness optimization based on surrogate models are focused on. Afterillustrating several methods for DOE and the construction of surrogate models, this paperanalyzes their application ranges. Finally, both the basic principles and solving process of theparticle swarm optimization method are summarized.
(2) Crashworthiness optimization of crash box structure based on its surrogatemodel during front collision.
The crashworthiness optimization with low velocity impact, according to thin-walledtaper tube with square cross section, which often appears as an energy absorbing part of crashbox, has been researched. A multi-objective optimization problem based on a combination ofCFE and SEA, has been put forward. Grooves are induced in the original structure. Afteranalyzed the relationship between energy absorption and crash force of structure withinducing grooves, the feasible design area of inducing grooves is obtained. The number,non-uniform intervals and depth of inducing grooves are taken as optimal parameters. Afterchosen sampling points reasonably, surrogate models are constructed by cubic polynomialsresponse surface method and radial basis function method respectively. Then the optimalnumber and distribution of inducing grooves are obtained by PSO method. FE analysisvalidates the effectiveness of this method. Results prove that compared with the structurewithout inducing groove, crashworthiness of the structure added inducing groovesscientifically is improved efficiently, which can be useful during the design of crash box.
(3) Crashworthiness optimization of car door structure based on its surrogatemodel during side collision.
Simulation for FE model of a certain car door structure during side collision has beenresearched. The curves of energy, collision contact force, deformation displacement andacceleration has been employed for analyzing the crashworthiness safety. Then, based on theuniform design and polynomial response surface method, surrogate models of the energy,maximum collision force and total mass of the car door structure under a special condition areconstructed respectively, as well as the thickness of planes are taken as variables. PSO methodis used as a tool for optimization of the surrogate models. As well as the mass and maximumcollision force of the original structure are treated as constraint conditions, the optimal designfor the main parts thickness of car door structure has been determined finally. With the design,one can effectively increase the energy of car door structure and improve the crashworthinessof the whole car.
(4) Analysis about the bending behavior of thin-walled beams with hexagonal andchannel sections and construction for simplified model of B pillar.
According to the researches on bending behavior of thin-walled beams with hexagonaland channel sections and the law for conservation of energy, formulas for calculating thedissipated energy of thin-walled beams through each plastic hinge line. The curve ofrelationship between the moment and rotation (i.e. M(θ)-θ) has been obtained. So therelative properties of non-linear rotation springs can be defined quickly by LS-DYNA. Bysetting the non-linear rotation springs into the zone appearing plastic hinges which are causedby the bending of B pillar, one can construct the simplified model of B pillar by non-linearbeams and rotation springs. After comparing the deformation effect, displacement curve andenergy curve of simplified model with those of detailed model, the effectiveness of simplifiedmodel is verified. The work is benefit to the construction for simplified model of vehicle andimprovement of effectiveness for crashworthiness optimization.
引文
[1] Paul DB, Clifford CC, Bahig BF, et al. Vehicle crashworthiness and occupantprotection[M]. Michigan：American Iron and Steel Institute，2004.
[2]乐玉汉.轿车车身设计[M].北京：高等教育出版社，2000.
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