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Integrated Computational Materials Engineering (ICME) for Metals: Using Multiscale Modeling to Invigorate Engineering Design with Science by Mark F. Horstemeyer

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7.10 DESIGN OPTIMIZATION WITH UNCERTAINTY OF THE AUTOMOTIVE CONTROL ARM

Different methods of design optimization have evolved over the years. The conventional design method (and still used today) is illustrated in Figure 7.87, where the following attributes are designated.

7.10.1 Conventional Design Optimization Method

1. Depends on the designer’s intuition, experience, and skill
2. Is a trial-and-error method
3. Is not easy to apply to a complex system
4. Does not always lead to the best possible design
5. Is a qualitative design

For the conventional redesign methodology, 22 boundary conditions were of concern for the Cadillac control arm. Two particular cases were most dominant however: 0.8 panic brake and the pothole strike. Although all 22 boundary conditions were run over a lengthy period of time, these two worst-case scenarios totally dominated the design stresses and damage states. Figures 7.88–7.90 show the Cadillac control arm boundary conditions and the resulting von Mises stresses and damage levels for the 0.8 g panic brake case. These values for the stresses and damage levels were used to optimize the control arm. Here, we define “optimized” to mean that we reduced the total weight of the control arm by reducing mass from regions that were overdesigned based on the local stress and damage state by the conventional method. Alternatively, we add mass to regions where the damage was the highest. Overall, a weight reduction of approximately 26% was achieved. Interestingly, ...

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