| Citation: |
HUANG Changxiong, CHEN Geng, HUANG Songhua, ZHANG Lele. Lightweight design and analysis of a combined seat bracket for a high-speed train based on SIMP−shakedown[J]. Chinese Journal of Engineering, 2024, 46(6): 1151-1160. DOI: 10.13374/j.issn2095-9389.2023.05.05.002
|
Next-generation high-speed trains are required to achieve higher speeds, enhanced safety, environmental friendliness, and cost-effectiveness. To meet these technical goals, reducing the structural weight to a certain extent is crucial. A standard seat has the following six components: a backrest, a seat cushion, two side and middle armrests, a rear pedal joined with front and rear tables, and a seat bracket. Among these components, the seat bracket, which connects the seat to the carriage, acts as the main load-bearing structure. In the current lightweight design of seat brackets in high-speed trains, the traditional approach is based on structural optimization techniques, often size or shape optimization, with the goal of achieving a desired global stiffness or local stress level, and the optimized structural configuration does not have the best performance under time-varied loads. Thus, it would show a conservative approach, inefficient material utilization, and difficulties in achieving an increasingly stringent lightweight design. On the one hand, the seat bracket’s main structure must have sufficient strength; on the other hand, the key components must not deform substantially under alternating loads because the work conditions under the operation are affected by the track and the application scenarios. Motivated by this, we propose a design and analysis method that integrates SIMP (solid isotropic microstructure with penalization) based topology optimization and direct method (DM) based parameter optimization techniques, where the former applies to the main structure and considers maximizing structural stiffness as a design objective with a prescribed volume fraction constraint and the latter applies to key components, that is, the L-shaped connector, and considers the shakedown limit as the design objective, where the corresponding parametric model is developed and the optimal result is obtained by the genetic algorithm (GA). Using this method, the main load-bearing pathway can be determined and geometric reconstruction design can be performed based on this pathway for the main structure. Compared with the original design, a weight reduction of 17% of the optimized assembled seat bracket is achieved for high-speed trains while ensuring that the mechanical performance meets the requirements. For DM-based parameter optimization design, the load-bearing capacity of the shakedown is increased by 7.8%, and structural efficiency is improved by 23%, with a 12.5% reduction in the material of the L-shaped connector. This study may provide valuable guidance for the lightweight design of similar structures under repeated variable loadings.
| [1] |
Yuce C, Karpat F, Yavuz N, et al. A case study: Designing for sustainability and reliability in an automotive seat structure. Sustainability, 2014, 6(7): 4608 doi: 10.3390/su6074608
|
| [2] |
Tang Z, Gu Z, Jia L, et al. Research on lightweight design and indirect hot stamping process of the new ultra-high strength steel seat bracket. Metals, 2019, 9(8): 833 doi: 10.3390/met9080833
|
| [3] |
Ju Y J, Jeon E S. Topology optimization of seat cushion frame with dissimilar materials for lightweight strength optimization. Int J Manuf Mater Mech Eng, 2019, 9(1): 1
|
| [4] |
Liu J K, Gaynor A T, Chen S K, et al. Current and future trends in topology optimization for additive manufacturing. Struct Multidiscip Optim, 2018, 57(6): 2457 doi: 10.1007/s00158-018-1994-3
|
| [5] |
顾宗阳, 蒋荣超, 刘大维等. CFRP−泡沫铝夹芯结构控制臂优化设计. 工程科学学报, 2023, 45(3):446
Gu Z Y, Jing R C, Liu D W, et al. Optimization design of the control arm of CFRP–aluminum foam sandwich structure. Chin J Eng, 2023, 45(3): 446
|
| [6] |
Bendsøe M P, Kikuchi N. Generating optimal topologies in structural design using a homogenization method. Comput Meth Appl Mech Eng, 1988, 71(2): 197 doi: 10.1016/0045-7825(88)90086-2
|
| [7] |
Bendsøe M P, Sigmund O. Material interpolation schemes in topology optimization. Arch Appl Mech, 1999, 69(9): 635
|
| [8] |
Stolpe M, Svanberg K. An alternative interpolation scheme for minimum compliance topology optimization. Struct Multidiscip Optim, 2001, 22(2): 116 doi: 10.1007/s001580100129
|
| [9] |
Young V, Querin O M, Steven G P, et al. 3D and multiple load case bi-directional evolutionary structural optimization. Struct Optim, 1999, 18(2): 183 doi: 10.1007/s001580050119
|
| [10] |
Sethian J A, Wiegmann A. Structural boundary design via level set and immersed interface methods. J Comput Phys, 2000, 163(2): 489 doi: 10.1006/jcph.2000.6581
|
| [11] |
Osher S, Sethian J A. Fronts propagating with curvature-dependent speed: Algorithms based on Hamilton-Jacobi formulations. J Comput Phys, 1988, 79(1): 12 doi: 10.1016/0021-9991(88)90002-2
|
| [12] |
Bourdin B, Chambolle A. Design-dependent loads in topology optimization. ESAIM Contr Optim Calc Var, 2003, 9: 19 doi: 10.1051/cocv:2002070
|
| [13] |
Wang M Y, Zhou S W. Phase field: A variational method for structural topology optimization. CMES Comput Model Eng Sci, 2004, 6(6): 547
|
| [14] |
Kobayashi M H. On a biologically inspired topology optimization method. Commun Nonlinear Sci Numer Simul, 2010, 15(3): 787 doi: 10.1016/j.cnsns.2009.04.014
|
| [15] |
Luo Y J, Bao J W. A material-field series-expansion method for topology optimization of continuum structures. Comput Struct, 2019, 225: 106122 doi: 10.1016/j.compstruc.2019.106122
|
| [16] |
Krog L, Tucker A, Rollema G. Application of topology, sizing and shape optimization methods to optimal design of aircraft components // 3rd Altair UK HyperWorks Users Conference. London, 2002
|
| [17] |
Orme M E, Gschweitl M, Ferrari M, et al. Designing for additive manufacturing: Lightweighting through topology optimization enables lunar spacecraft. J Mech Des, 2017, 139(10): 100905 doi: 10.1115/1.4037304
|
| [18] |
Zhu J H, Zhang W H, Xia L. Topology optimization in aircraft and aerospace structures design. Arch Comput Meth Eng, 2016, 23(4): 595 doi: 10.1007/s11831-015-9151-2
|
| [19] |
Cole T J, Bassler J, Cooper S, et al. The challenges of designing a lightweight spacecraft structure for landing on the lunar surface. Acta Astronautica, 2012, 71: 83 doi: 10.1016/j.actaastro.2011.08.003
|
| [20] |
Deaton J D, Grandhi R V. A survey of structural and multidisciplinary continuum topology optimization: Post 2000. Struct Multidiscip Optim, 2014, 49(1): 1 doi: 10.1007/s00158-013-0956-z
|
| [21] |
Huang S H, Xu Y G, Bezold A, et al. A direct method-based strength evaluation of the cast aluminum beam used in a high-speed train. J Rail Rapid Transit, 2019, 233(9): 896 doi: 10.1177/0954409719825515
|
| [22] |
Li W J, Zeng F M, Chen G, et al. Shakedown analysis for structural design applied to a manned airtight module. Int J Press Vessels Pip, 2018, 162: 11 doi: 10.1016/j.ijpvp.2018.02.006
|
| [23] |
Kanerva M, Sarlin E, Hållbro A, et al. Plastic deformation of powder metallurgy tungsten alloy foils for satellite enclosures // 30th Congress of the International Council of the Aeronautical Sciences ICAS. Daejeon, 2016: 23
|
| [24] |
Chen G, Bezold A, Broeckmann C, et al. On the statistical determination of strength of random heterogeneous materials. Compos Struct, 2016, 149: 220 doi: 10.1016/j.compstruct.2016.04.023
|
| [25] |
Hachemi A, Chen M, Chen G, et al. Limit state of structures made of heterogeneous materials. Int J Plast, 2014, 63: 124 doi: 10.1016/j.ijplas.2014.03.019
|
| [26] |
Weichert D, Maier G. Inelastic Analysis of Structures under Variable Loads: Theory and Engineering Applications. Berlin: Springer Science & Business Media, 2000
|
| [27] |
Melan E. Zur plastizität des räumlichen kontinuums. Ingenieur-Archiv, 1938, 9(2): 116 doi: 10.1007/BF02084409
|
| [28] |
刘应华, 陈钢, 徐秉业. 结构的塑性分析与含体积型缺陷压力容器和管道的失效评定. 固体力学学报, 2010, 31(6):643
Liu Y H, Chen G, Xu B Y. Plastic analysises of structures and failure assessment of pressure vessels and piping with volumetric defects. Chin J Solid Mech, 2010, 31(6): 643
|
| [29] |
Surmiri A, Nayebi A, Rokhgireh H. Shakedown-ratcheting analysis of Bree's problem by anisotropic continuum damage mechanics coupled with nonlinear kinematic hardening model. Int J Mech Sci, 2018, 137: 295. doi: 10.1016/j.ijmecsci.2018.01.030
|
| [30] |
Gao B, Chen X, Chen G. Ratchetting and ratchetting boundary study of pressurized straight low carbon steel pipe under reversed bending. Int J Press Vessels Pip, 2006, 83(2): 96 doi: 10.1016/j.ijpvp.2005.12.002
|
| [31] |
全国锅炉压力容器标准化技术委员会. GB/T19624—2019在用含缺陷压力容器安全评定. 北京:中国标准出版社, 2019
China Standardization Committee on Boilers and Pressure Vessels. GB/T19624—2019 Safety Assessment of Pressure Vessels with Defects in Service. Beijing: Standard Press of China, 2019
|
| [32] |
Zhuang Y, Wang K Y, Li H X. Shakedown solutions for ballasted track structure under multiple uniform loads. Transp Geotech, 2020, 22: 100298 doi: 10.1016/j.trgeo.2019.100298
|
| [33] |
王康宇, 庄妍, 张占荣, 等. 多个列车轮载作用下铁路道床结构安定性分析. 中南大学学报(自然科学版), 2020, 51(8):2343
Wang K Y, Zuang Y, Zhang Z R. Structural shakedown analysis of ballasted track structure under multiple train wheel loads. J Cent South Univ Sci Technol. 2020, 51(8): 2343
|
| [34] |
Chen H F, Ponter A R S. A method for the evaluation of a ratchet limit and the amplitude of plastic strain for bodies subjected to cyclic loading. Eur J Mech A/Solids, 2001, 20(4): 555 doi: 10.1016/S0997-7538(01)01162-7
|
| [35] |
Chen H F, Chen W H. Recent development and application of the linear matching method for design limits in plasticity and creep: An overview. Direct Meth Limit Stat Struct Mater, 2014: 257
|
| [36] |
Spiliopoulos K V, Panagiotou K D. The residual stress decomposition method (RSDM): A novel direct method to predict cyclic elastoplastic states. Direct Meth Limit Stat Struct Mater, 2014: 139
|
| [37] |
Spiliopoulos K V, Panagiotou K D. An enhanced numerical procedure for the shakedown analysis in multidimensional loading domains. Comput Struct, 2017, 193: 155 doi: 10.1016/j.compstruc.2017.08.008
|
| [38] |
Peng H, Liu Y H, Chen H F, et al. Shakedown analysis of engineering structures under multiple variable mechanical and thermal loads using the stress compensation method. Int J Mech Sci, 2018, 140: 361 doi: 10.1016/j.ijmecsci.2018.03.020
|
| [39] |
秦方, 张乐乐, 黄松华等. 基于均匀化理论的复合材料安定性分析方法. 工程科学学报, 2019, 41(12):1558
Qin F, Zhang L L, Huang S H, Chen G. Shakedown analysis method for composites based on homogenization theory. Chin J Eng, 2019, 41(12): 1558
|
| [40] |
Kammoun Z, Smaoui H. A direct method formulation for topology plastic design of continua. Direct Meth Limit Shakedown Analysis Struct, 2015: 47
|
| [41] |
Kammoun Z, Fourati M, Smaoui H. Direct limit analysis based topology optimization of foundations. Soils Found, 2019, 59(4): 1063 doi: 10.1016/j.sandf.2019.05.003
|
| [42] |
Boissier M, Deaton J D, Beran P A, et al. Elastoplastic topology optimization of cyclically loaded structures via direct methods for shakedown. Struct Multidiscip Optim, 2021, 64: 189 doi: 10.1007/s00158-021-02875-6
|
| [43] |
Li K, Cheng G D. Structural topology optimization of elastoplastic continuum under shakedown theory. Numerical Meth Eng, 2022, 123(19): 4459 doi: 10.1002/nme.7041
|
| [44] |
Huang S H, Xu Y G, Zhang L L, e al. A shakedown strength based parametric optimization technique and its application on an airtight module. Chin J Mech Eng, 2022, 35(1): 1 doi: 10.1186/s10033-021-00666-0
|
| [45] |
冯智莉, 易国洪, 李普山, 等. 并行化遗传算法研究综述. 计算机应用与软件, 2018, 35(11):1 doi: 10.3969/j.issn.1000-386x.2018.11.001
Feng Z L, Yi G H, Li P H, et al. Research review of parallel genetic algorithm. Comput Appl Softw, 2018, 35(11): 1 doi: 10.3969/j.issn.1000-386x.2018.11.001
|
| [46] |
Chen G, Wang X, Zhou Z Y, et al. Shakedown analysis of a reusable space capsule. Int J Mech Sci, 2023, 244: 108028 doi: 10.1016/j.ijmecsci.2022.108028
|
| [47] |
铁道行业内燃机车标准化技术委员会. TB/T 3263—2011动车组乘客座椅. 北京:国家铁路局, 2011
The Railway Industry Diesel Engine Standardization Technical Committee of the China. TB/T 3263—2011 Passenger Seat for Powered Car Train-set. Beijing: State Railway Administration, 2011
|
| 1. |
原帅超，王建峰，段宇航，郝璐静，占小红. 基于变密度法的SLM增材制造无人机承载接头结构拓扑优化设计. 工程科学学报. 2025(01): 56-65 .
 本站查看
|
Supported by:
Beijing Renhe Information Technology Co., Ltd.
DownLoad: