LIGHTWEIGHT STRUCTURAL OPTIMIZATION BASED ON MULTI-CELL MULTI-CORNER CRASH BOX CONFIGURATION USING DESIGN FOR SIX SIGMA METHODOLOGY
Engineers across the globe have been racing to design the most efficient energy absorbing structure of a vehicle as it is highly essential on ensuring passenger safety during impacts. This thesis mainly focuses on the design optimization of Multi cell – Multi corner crash box for general applicat...
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| Format: | Final Project |
| Language: | Indonesia |
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| Online Access: | https://digilib.itb.ac.id/gdl/view/69585 |
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| Institution: | Institut Teknologi Bandung |
| Language: | Indonesia |
| Summary: | Engineers across the globe have been racing to design the most efficient
energy absorbing structure of a vehicle as it is highly essential on ensuring
passenger safety during impacts. This thesis mainly focuses on the design
optimization of Multi cell – Multi corner crash box for general application. On this
particular thesis, different geometries, shapes, cell configurations and material will
be modelled and analysed based on Taguchi’s Design for Six – Sigma method. The
design dimensions are bounded by uniform size of aluminium sheets with a width
x length of 80 X 120 mm The parameter acts as the controllable factors which are
thickness, shape, multi-cell configuration, material (Al-606X T-Y) and trigger
location. Each parameter is given four levels and each run are given 3 replicates
with an error of 5% thickness on the model to mimic manufacturing error to the
simulation. The final design achieved from the optimization of Taguchi’s Design
for Six-Sigma method will be evaluated and modelled for the final test to ensure
that the product is indeed highly efficient in absorbing energy in compared to the
existing data. The control factors are analysed by Analysis of Variance (ANOVA)
method in order to determine the contribution of each factor in optimizing SEA value. The modelling was done by Finite Element Analysis software named LSDyna,
by simulating an impact test for each crash box designs bounded by the same
surface area and all calculations and formulations of data are done in Excel. This
research produced two optimum designs based on the response chart plotted from
the Taguchi method and both designs has successfully to exceed the predicted gain.
Finally, the best design achieved has managed to absorb just over 110 kj which produced almost 10 db of gain from the prediction. By using ANOVA, it is determined that the material selection contributes the most in optimizing specific energy absorption value of a crash box. Overall, the 4 x 4 squared crash box with thickness of 2.0 mm made of Al-6066 T4 sheet with the trigger located at H, is
chosen as the most optimum design. |
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