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Spot-Weld Fatigue Optimization
KTH, Skolan för teknikvetenskap (SCI), Hållfasthetslära (Inst.), Hållfasthetslära (Avd.).
KTH, Skolan för teknikvetenskap (SCI), Hållfasthetslära (Inst.), Hållfasthetslära (Avd.).
2018 (Engelska)Självständigt arbete på avancerad nivå (masterexamen), 20 poäng / 30 hpStudentuppsats (Examensarbete)
Abstract [en]

The purpose of this thesis project is to develop a methodology that can be used to minimize the number of spot-welds in a mechanical structure, this is done in a reliable manner via optimization methods. The optimization considers fatigue life in spot-welds and also stiffness and eigenfrequency values. The first chapter of this thesis presents a spot-weld fatigue model proposed by Rupp (1995), common FEmodels of spot-welds and also important aspects about structural optimization in general. The second chapter further describes how topology optimization and size (parameter) optimization are applied on a simple multi-weld model with respect to the aforementioned structural constraints. The topology optimization is later used on a full-size car model, while the size optimization is used to optimize the multiweld model by adding an non-linear structural constraint - a crash indentation constraint. The spot-weld fatigue model proposed by Rupp (1995), is also verified by comparing FE results using different FE-models of spot-welds compared to fatigue data by Long and Khanna (2007). Both optimization methods successfully minimize the total amount of spot-welds on the multi-weld model. The topology optimization,accompanied with thegradient based MFD algorithm,minimizes th etotal spot-welds with around 15% and 3% on the multi-weld model and car body respectively. The size optimization, using design of experiments and response surfaces, manage storeduce the number of welds in the multi-weldmodel by 25%. However, with the size optimization the computational time is several orders of magnitude longer-even without the formulation of the crash constraint. The fatiguespot-weld model fares reasonably well compared to the experimental fatigue data, regardless of the FE model of the spot-weld. It is concluded that the ACM model would be recommended based on its compatibility with fatigue and optimization methods, mesh-independence and also other studies have shown its ability to represent stiffness and eigenfrequency correctly.

Ort, förlag, år, upplaga, sidor
2018. , s. 76
Serie
TRITA-SCI-GRU ; 219
Nationell ämneskategori
Teknisk mekanik
Identifikatorer
URN: urn:nbn:se:kth:diva-232529OAI: oai:DiVA.org:kth-232529DiVA, id: diva2:1237800
Externt samarbete
Combitech CAE
Ämne / kurs
Hållfasthetslära
Handledare
Examinatorer
Tillgänglig från: 2018-08-10 Skapad: 2018-08-10 Senast uppdaterad: 2018-08-10Bibliografiskt granskad

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