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Abstract
To achieve lightweight vehicle door, this paper presents a novel design with a hybrid material tailor-welded structure
(HMTWS). A multiobjective optimization procedure is adopted to generate a set of solutions, in which the door stiffness
and mass are taken as objective functions, and the material types and plate thicknesses are regarded as the discrete and
continuous design variables, respectively. To improve the optimization efficiency, Kriging algorithm is used for generating
surrogate model through a sequential sampling strategy. The non-dominated sorting genetic algorithm II (NSGA-II) is
employed to perform the multiobjective optimization. It is found that for the same computational cost, the sequential
sampling strategy can yield more accurate optimization results than the conventional one-step sampling strategy. Most
importantly, HMTWS is found more competent than the traditional thin-walled configurations made of steel or other
lighter mono-materials for maximizing the usage of materials and stiffness of the vehicular door structures.
Keywords
Hybrid materials tailor-welded structure, tailor-welded blank, vehicular door, sequential sampling, multiobjective opti-
mization, Kriging model
different materials, such as aluminum, magnesium, This paper takes into account both TWB configur-
steel and carbon fiber, were utilized as the potential ation and hybrid material usage, aiming to design a
candidates for selection. Ince et al.12 investigated the novel hybrid materials tailor-welded structure
impact behaviors of the crash boxes made of steel and (namely, HMTWS) for vehicle door structure using
aluminum materials experimentally and numerically, MOO, in which the Kriging surrogate technique and
and they then optimized the hybrid crash box to min- sequential sampling-based optimization work
imize the weight. together to reduce the computational cost. The rest
To achieve better combination of dissimilar mater- of the paper is organized as follows. The following
ials, substantial efforts have been devoted to the devel- section describes the finite element modeling of
opment of different tailored welding technologies. For TWB and hybrid materials tailor-welded structure
example, Schubert et al.13 exemplified the prototype as well as defines the specific optimization problem.
structures made of aluminum, titanium, magnesium The Design optimization methodology section 3
and their combinations by using laser beam joint tech- presents the methodology adopted in the door
nology. Merklein and Giera14 performed butt joints of design case, including the Non-dominated Sorting
dissimilar steel and aluminum sheets with laser- Genetic Algorithm II (NSGA-II), Kriging approxima-
assisted friction stir welding. Shigematsu et al.15 tion, and sequential sampling-based MOO. The next
explored TWBs comprised of aluminum and magne- section provides the results and discussions of the
sium alloys, in which friction stir welding process was TWB door structural design with hybrid materials.
employed. Sahin16 welded austenitic stainless steel Finally, some conclusions are drawn in the last
and aluminum materials using the friction welding section.
technology. Although there have been some studies
available on joining dissimilar materials, the investi-
gations into optimization of TWB structures with Design optimization of a HMTWS vehi-
hybrid materials in automotive industry have not cle door
been well reported yet in literature. Numerical modeling and experimental validation of
Most (if not all) real-life engineering problems
are characterized by multiple conflicting require-
the door structure19
ments, between which an appropriate trade-off As illustrated in Fang et al.,19 the finite element (FE)
should be made through multiobjective optimization models of a vehicle door, subjected to four different
(MOO).17–19 Instead of seeking a unique optimal solu- load conditions, i.e. lower lateral, upper lateral, verti-
tion, MOO often generates a spectrum of solutions to cal sag, and free–free boundary conditions, and the
provide decision-makers with more insightful first three are established in Figure 1. The FE models
information. are run in commercial code MSC.NASTRAN.20
Figure 1. Loading conditions for door stiffness analyses. (a) Lower lateral, (b) upper lateral, and (c) vertical sag.
Table 3. Details of NSGA-II parameters used in this study. modeling starts with proper selection of sampling
points. In this paper, the optimal Latin Hypercube
NSGA-II Parameter name Value
sampling (OLHS)38 is implemented to generate initial
Population size 100 sample data.
Number of generations 500 As one commonly used surrogate approach,
Crossover probability 0.9 Kriging model was originally developed for mining
Mutation probability 0.1 and geo-statistical applications involving spatially
Distribution index for crossover 2.0
and temporally correlated data. The Kriging model
assumes the deterministic response of a system to be
Distribution index for mutation 20
a stochastic process function yðxÞ, consisting of a
regression model and a stochastic error39
20
m
f
15 Dsag
Dupper
Dlower
ε/%
10
0
0 5 10 15 20 25
Iteration NO.
7
Iteration 0
Iteration 22
5
Dsag / mm
structure.
1
continue the sequential update of Kriging model 10 15 20 25 30 35 40 45 50
m / kg
and optimization from Step 1.
The error metric can be defined as Figure 6. Comparison of Pareto frontiers before and after
iterations.
Xn
" ¼ 1=n yi y^ i =yi ð3Þ
i¼1
where yi and y^ i are the FEA value and the corres- and optimization is adopted. During the entire
ponding surrogate approximate value, respectively, sequential process the convergence history is summar-
and n is the number of the selected validation ized in Figure 5. It can be seen that after 22 iterations
points. In this study, the optimization is considered of sequential sampling and optimization procedure,
converged adequately if the error metric is smaller the objectives and constraints converge adequately.
than 1% (i.e. " 5 1 %) for each objective and con- Specifically, the errors calculated with 11 validation
straint function. points gradually decrease though some fluctuations
In summary, the proposed optimization design are observed during the iterations. After the optimiza-
procedure for the TWB door structure can be depicted tion process, the errors converge to the predefined
in the flowchart in Figure 4. level (" < 1%).
Figure 6 compares the Pareto frontiers before and
after the sequential sampling iterations (i.e. iterations
Results and discussions 0 and 22, respectively). It is interesting to note that
there are large differences between them in terms of
Iteration history of sequential sampling procedure
objective ranges. After the sequential optimization the
In this study, the sample size of the initial DoE train- Pareto frontier actually moves up and right in the
ing points is 50. The initial errors were substantially objective space. From both Figures 6 and 7, the
higher than a satisfactory level (" 5 1% here) and sequential procedure is necessary for generating an
thus the procedure of sequential sampling update accurate Pareto frontier in this case.
Advantage of sequential sampling-based Figure 8 plots the accuracy comparison of the opti-
mal solutions generated from these two different sam-
optimization pling strategies. Eleven optimal solutions on the
To compare the sequential sampling based optimiza- corresponding Pareto frontiers (Figure 7) are used
tion with the conventional one-step sampling-based for the comparative analysis. It is evident that for
optimization, the corresponding Pareto frontiers are all the indicators (i.e. the objectives and constraints),
also plotted together in Figure 7. The training points the sequential sampling based optimization generates
in the one-step sampling strategy are generated using much more accurate solutions, in which all the mod-
OLHS, and the sample size is assigned the same as eling errors based on sequential sampling strategy are
that of the total sample points (i.e. 303 (¼ lower than 1% (as seen in Figure 5), whereas the
50 þ 2311) points) from the sequential sampling errors from the one-step sampling procedure are
procedure so that the two different sampling strategies much larger, especially for the vertical sag stiffness
have the same computational cost in terms of the full whose error is up to around 5%, which is considered
finite element analyses. Although a clear difference unacceptable in this design case.
can be observed in these two Pareto curves, it remains
unknown which is better and more realistic from
modeling accuracy perspective.
Optimization results
Tables 4–6 give the 11 optimal solutions and their
corresponding objectives and constraints of the
3.5 sequential sampling based optimization. It can
One-step Sampling based Optimization
Sequential Sampling based Optimization
found that the individual error of each optimum is
fairly small compared to the FEA value with
3 Kriging prediction value. More importantly, com-
pared to the original steel door structure (see Table
1), the novel HMTWS obtained from optimization
2.5
can improve the objectives (i.e. decrease the mass
and improve vertical sag stiffness), and simultan-
Dsag / mm
No. M1 M2 M3 M4 M5 T1 T2 T3 T4 T5
M Dsag
No. Kriging (kg) FEA (kg) Error (%) Kriging (mm) FEA (mm) Error (%)
f Dupper Dlower
No.
Kriging (Hz) FEA (Hz) Error (%) Kriging (mm) FEA (mm) Error (%) Kriging (mm) FEA (mm) Error (%)
The Pareto frontiers of structures made of three either better sag stiffness can be obtained for the
mono-materials and HMTWS are displayed together same mass or lower mass can be obtained for
in Figure 9. Apparently, HMTWS is much more pro- the same sag stiffness. Besides, a simple substitution
mising than any of mono-material structures, i.e. of steel with lighter materials, such as magnesium or
4
The non-dominated sorting genetic algorithm II
(NSGA-II) was employed to generate Pareto fron-
tiers, integrated with the sequential sampling-based
3.305
3.5 metamodeling technique. From the optimization
results, we can come to the following specific
3.300 conclusions.
3
2.5
3.295 single lighter material structures, the novel
15.915 15.920 15.925 15.930
HMTWS door with both TWB technique and
Steel hybrid materials can significantly improve the
2
Aluminium design objectives of vertical sag stiffness and light-
Magnesium weight, while satisfying all the other stiffness
HMTWS
1.5 constraints.
2. Compared with the one-step sampling strategy
that has the similar computational cost, the
1
15 20 25 30 35 40 45 50
sequential sampling strategy yielded more accur-
m / kg ate and realistic optimal solutions.
Figure 9. Pareto frontier comparison of HMTWS and differ- Declaration of Conflicting Interests
ent single-material structures.
The author(s) declared no potential conflicts of interest with
respect to the research, authorship, and/or publication of
this article.
aluminum, can reduce the mass only within a very
narrow range of sag vertical stiffness as shown in
Funding
the Pareto space. In other words, compared with
steel, a magnesium door can reduce the mass only The author(s) disclosed receipt of the following financial
support for the research, authorship, and/or publication
when vertical sag deformation is around 3.3 mm,
of this article: The supports from the National Natural
and an aluminum door can do so only when vertical Science Foundation of China (51575172), the Hunan
sag deformation lies in between 2.4 and 2.7 mm. Provincial Science Foundation of China (13JJ4036), the
It should be pointed out that in the sequential sam- Doctoral Fund of Ministry of Education of China
pling and modeling procedure, these 11 validation (20120161120005) are acknowledged. The first author
points are selected from the current Pareto frontier is a recipient of the doctoral scholarships from both
uniformly. Addition of these optimal validation China Scholarship Council (CSC) and the University of
points to the training data set allows to particularly Sydney.
enhance the modeling accuracy near the optimum
domain. Such a sampling bias is generally considered
positive to the design optimization and it enables a References
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