Topological optimization of the load-bearing structure of the safety cage

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Abstract

BACKGROUND: The conducted study of the stress-strain state of the safety cage developed in compliance with the requirements of the Russian Automotive Federation (RAF) showed that the structure does not meet the requirements of deformation after side impact. Therefore, the basic design demands additional study with the use of state-of-the-art approaches of development.

AIMS: This paper considers the issue of finding the optimal design of a racing car safety cage based on topological optimization in order to meet the rigidity requirements while minimizing the mass.

METHODS: To implement the topological optimization method, mathematical modeling was carried out using the Structural Optimization module of the Ansys software package. Tests regulated by the RAF were selected to test the effectiveness of the optimized design. To evaluate the results, a comparison of the results of test simulation before and after optimization was made.

RESULTS: The mass of the optimized design has decreased by 6% relative to the original. Rigidity of the structure with loading at main and front rollbars remained the same. Deformation of the optimized design with side loading of the main rollbar was reduced by 98%.

CONCLUSIONS: The results of modeling the tests regulated by the RAF showed that the design of the safety cage, developed on the basis of the material pseudo-density map obtained as a result of topological optimization, meets the requirements for permissible deformation. Further study of the stress-strain state of the safety cage should be carried out in conjunction with the finite element model of the vehicle to take into account the loads arising as a result of body deformation.

About the authors

Daniil A. Zhitelev

Bauman Moscow State Technical University

Author for correspondence.
Email: daniil2699@mail.ru
ORCID iD: 0000-0002-8080-1419
SPIN-code: 6751-6872

Student of the Multipurpose Tracked Vehicles and Mobile Robots Department

Russian Federation, 5, 1 2nd Baumanskaya street, 105005 Moscow

Tihon D. Pozdnyakov

Bauman Moscow State Technical University

Email: t.pozdnyakov@bmstu.ru
ORCID iD: 0000-0001-8966-1806
SPIN-code: 9150-2654

Senior Lecturer of the Multipurpose Tracked Vehicles and Mobile Robots Department

Russian Federation, 5, 1 2nd Baumanskaya street, 105005 Moscow

Dmitrii A. Sulegin

Bauman Moscow State Technical University

Email: d_sulegin@bmstu.ru
ORCID iD: 0000-0003-3359-3829
SPIN-code: 6960-2909

Associate Professor, Cand. Sci. (Tech.), First Vice Dean of the Mechanical Engineering Faculty

Russian Federation, 5, 1 2nd Baumanskaya street, 105005 Moscow

References

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Supplementary files

Supplementary Files
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2. Fig. 1. Deformed state with horizontal loading of the main rollbar.

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3. Fig. 2.  The beam model.

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4. Fig. 3. The surface model.

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5. Fig. 4. The result of topological optimization.

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6. Fig. 5. The safety cage based on optimization results.

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7. Fig. 6. The finite element model of the safety cage.

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8. Fig. 7. The steel 20 bilinear characteristic.

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9. Fig. 8. Deformed state with loading at the main rollbar.

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10. Fig. 9. Deformed state with loading at the front rollbar.

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11. Fig. 10. Deformed state with horizontal loading at the main rollbar.

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