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The advent of various structural optimization methods has made the process of deriving efficient lightweight designs for complex structures under multiple load conditions far more attainable than ever before. Three of these methods, namely sizing, topology and topometry optimization have been used extensively in the structural optimization of body-in-white structures. While all these techniques have their unique advantages, they provide different solutions to the posed problem. In this paper, we examine how best these optimization techniques can be used to derive a more efficient design within a linear domain, through a case study. Depending on the starting point of the design, all three techniques can play a vital role in making design decisions.

The development of light-weight vehicles that are safe and durable has become an imperative for the automotive industry. The complexity of the vehicle design, the variety of available material grades, and the disparate needs (imposed by energy absorption, intrusion resistance, durability and stiffness) can make the search of light-weight design quite daunting and tedious. Optimization techniques, used in conjunction with CAE analyses, can be effective in arriving at a viable design by searching a wide spectrum of alternatives in the design space. Through a case study involving mass and material optimization, it is shown that utilization of advanced high-strength steels (AHSS) can be exploited judiciously to arrive at strong, stiff, and durable automotive structures. Multiple linear load cases, along with a non-linear roof crush load are considered in this study.