Computational Efficiency Improvements in Topography Optimization Using Reanalysis 2016-01-1395

To improve fuel economy, there is a trend in automotive industry to use light weight, high strength materials. Automotive body structures are composed of several panels which must be downsized to reduce weight. Because this affects NVH (Noise, Vibration and Harshness) performance, engineers are challenged to recover the lost panel stiffness from down-gaging in order to improve the structure borne noise transmitted through the lightweight panels in the frequency range of 100-300 Hz where most of the booming and low medium frequency noise occurs. The loss in performance can be recovered by optimized panel geometry using beading or damping treatment. Topography optimization is a special class of shape optimization for changing sheet metal shapes by introducing beads. A large number of design variables can be handled and the process is easy to setup in commercial codes. However, optimization methods are computationally intensive because of repeated full-order analyses. In this paper, we propose using a Modified Combined Approximations (MCA) reanalysis method integrated with topography optimization to improve the computational efficiency. Using a tire tub example, we will demonstrate that the topography optimization can become more efficient if integrated with reanalysis.