Shape Optimization of Sheet Metal Structures against Crash

1981 ◽  
Author(s):  
Ture Åkerström ◽  
Clas Jernström ◽  
Tomasz Wierzbicki
Keyword(s):  
Shape Optimization ◽  
Sheet Metal ◽  
Metal Structures

Autonomes Oberflächenschleifen von Aluminium-Anbauteilen/Autonomous grinding of lightweight constructions

2020 ◽  
Vol 110 (07-08) ◽  
pp. 507-510
Author(s):  
Jan-Oliver Brassel ◽  
Severin Hönle ◽  
Jürgen Fleischer ◽  
Hannah Pulli
Keyword(s):  
Sheet Metal ◽  
Metal Surfaces ◽  
Surface Finishing ◽  
Technological Solution ◽  
Metal Structures ◽  
Car Body

Zum Erfüllen der hohen Anforderungen an fehlerfreie Blechteiloberflächen werden häufig manuelle Aufwendungen in die Fertigstellung der Bauteile investiert. Mit Blick auf Produktivität und Wiederholgenauigkeit sollen Teilumfänge der Fertigstellung automatisiert werden. Inhalt dieses Beitrags ist die Konzeption einer Prozesskette zum autonomen Schleifen von Karosseriebauoberflächen sowie die Betrachtung eines Algorithmus zur Berechnung der Bearbeitungsreihenfolge.   Flawless paintwork on car body structures does require defect-free sheet metal surfaces. Therefore, mainly inline and manual refinement efforts are made to surface finishing the single car bodies before painting. Targeting productivity and repeat accuracy can make it necessary to automate certain amounts of this labour-intensive process. This paper presents a technological solution for autonomously grinding sheet metal structures as well as detailing an algorithm for calculating the sequence of steps for autonomous grinding.

scholarly journals Manufacturing of Innovative Self-supporting Sheet-metal Structures Representing Freeform Surfaces

Procedia CIRP ◽  
2014 ◽  
Vol 18 ◽  
pp. 51-56 ◽  
Author(s):  
D. Bailly ◽  
M. Bambach ◽  
G. Hirt ◽  
T. Pofahl ◽  
R. Herkrath ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Freeform Surfaces ◽  
Metal Structures

A New Approach for Optimization of Sheet Metal Components

2005 ◽  
Vol 6-8 ◽  
pp. 255-262 ◽  
Author(s):  
A. Albers ◽  
H. Weiler ◽  
D. Emmrich ◽  
B. Lauber
Keyword(s):  
Finite Element ◽  
Mathematical Programming ◽  
Sheet Metal ◽  
Optimization Method ◽  
Optimality Criteria ◽  
Body Parts ◽  
Bending Stress ◽  
Element Analysis ◽  
Metal Structures ◽  
Severe Difficulty

Beads are a widespread technology for reinforcing sheet metal structures, because they can be applied without any additional manufacturing effort and without significant weight increase. The two main applications of bead technology are to increase the stiffness for static loading conditions and to reduce the noise and vibrations for dynamic loadings. However, it is difficult to design the bead patterns of sheet metal structures due to the direction-controlled reinforcement effect of the beads. A wrong bead pattern layout can even weaken the properties of the structure. In the past, the designs were predominantly determined empirically or by the use of so called bead catalogues. Recently, different optimization approaches for bead patterns were developed, which are based upon classical mathematical programming optimization algorithms together with automatically generated shape basis vectors. However, these approaches usually provide only vague suggestions for the designs. One of the most severe difficulty with these approaches is to transfer the optimized results into manufacturable designs. Furthermore, another severe difficulty is that the optimization problem is non-convex, which frequently leads the mathematical programming algorithms into a local optima and thus to sub-optimal solutions. The investigations in this article show an optimization method, which within a few iterations leads to bead structures with excellent reinforcement effects using optimality criteria based approach. Generally, the results can be transferred without large effort into a final design. The new optimization method calculates the distribution of the bending stress tensor and the principal bending stresses based upon the results of a finite element analysis. The bead orientations are calculated by the trajectories of the principal bending stress with the largest magnitude. The beads are projected on to the mesh of the component using geometric form functions of the desired bead cross section. A local bead ratio of 50% (defined as average area of the beads in relation to total area of the sheet) is used by the algorithm to determine the maximum moment of inertia. The proposed algorithm is numerical implemented in the optimization system TOSCA and available for being applied with the following finite element solvers: ABAQUS, ANSYS, I-DEAS, NX Nastran, MSC.Nastran, MSC.Marc and PERMAS. The optimization algorithm is successfully applied to static and dynamic real world problems like car body parts, oil pans and exhaust mufflers. In the present work several academic and industrial examples are presented.

Rapid Electromagnetic Induction Bonding of Composites, Plastics, & Metals

1988 ◽  
Vol 124 ◽  
Author(s):  
John D. Buckley ◽  
Robert L. Fox
Keyword(s):  
Low Power ◽  
Sheet Metal ◽  
Electromagnetic Induction ◽  
Metal Structures ◽  
Bonding System ◽  
Reinforced Composite ◽  
Entire Structure ◽  
Standard Press

ABSTRACTA rapid electromagnetic induction bonding system has been developed that joins composites, plastics, metals, and combinations of these materials. The equipment is self-contained, low power (100–400 watts) and portable. Gangs of bonders have been used as a seem welder to rapidly join plastic reinforced composite and sheet metal. Structures can be bonded in a factory or in the field. Bonding times for laboratory specimens have been cut by a factor of 10 to 100 times compared to standard press or autoclave bonding. This type of equipment allows for applying heat directly to the bond lines and/or the adherends without heating the entire structure, supports, and fixtures of a bonding assembly.The bonder's portability and low power requirements allow for its use on site in any type of climate with power supplied by a variety of portable sources.

Upfront Durability CAE Analysis for Automotive Sheet Metal Structures

1996 ◽  
Author(s):  
Hari Agrawal ◽  
Al Conle ◽  
Ravi Gopalakrishnan ◽  
Cliff Rivard ◽  
Lokesh Juneja
Keyword(s):  
Sheet Metal ◽  
Metal Structures ◽  
Automotive Sheet ◽  
Cae Analysis
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