Higher-order modeling of a thin-walled beam with a welded multicell cross-section and its application to welding line optimization

Thin-walled multicell structures observed in vehicle frames are partially welded to lower the welding process cost while maintaining their overall structural stiffness comparable to those of fully-welded multicell structures. A fast and reliable beam-based model for analyzing such structures is required in the concept stage of the design process. In this investigation, an analysis method for a thin-walled beam of a multi-cell cross-section partially welded along its axial direction is newly established using a higher-order beam theory (HoBT). Our approach uses the Lagrange multipliers to impose the partial welding condition along the common edges of multiple thin-walled closed sections using the threedimensional field derived from a higher-order beam theory. The developed method in this study can be an accurate and effective alternative without full finite element analysis employing shell and solid elements. To find the optimal welding locations, we introduced binary design variables parameterized through their corresponding welding constraints to identify the status of welding or non-welding along a candidate welding line. A genetic algorithm is adopted to solve optimization problems. After establishing the analysis method and optimization technique, their validity was checked using double-cell and triple-cell sectioned beams and beam frame structures, including a bus structure. The stiffnesses of the structures with optimized partial welding lines (20%) drop less than 6% from those of fully welded counterparts.