Structural topology optimization for surrogate automotive body design

An optimization tool is described for designing physically realizable surrogate automotive body structures for use in laboratory testing of chassis components and systems. With this tool, various automotive systems can be independently designed, developed and verified physically by employing the optimally designed surrogate body structures that meet the required compliance and frequency characteristics of prototype body structure. A multi-objective optimization formulation is developed and is instantiated using a 3D (partially) grounded frame element structure. In addition, lumped masses are included in the optimization process to better match frequency and compliance design targets. The performance of the methodology is highlighted by presenting the design, fabrication, and experimental validation of atypical surrogate body structure design problem for chassis component evaluation.