EngOpt 2016 - 5th International Conference on Engineering Optimization

Iguassu Falls, Brazil, 19-23 June 2016.

Topology optimization vehicle chassis: Software applied to optimization trucks

and buses chassis stringer in automotive industry

LIXANDRAO FERNANDO, P. H.; SANTOS, G. A.; NAKAMOTO, F. Y.

Department of Mechanical Engineering, IFSP, SP, Brazil

e-mail: paulohlf@yahoo.com.br/givanildo@ifsp.edu.br/nakamoto@ifsp.edu.br

Abstract
The necessity to reduce production costs in the automotive industry is strongly investigated by product
engineers. For this reason, engineers and designers search in other areas modern techniques that can be
improved or used in their projects, using computational methods for optimization applied to the part design.
The application of this technique is a further step to the use of CAE software currently used on a large scale
in the automotive industry. This actual technique is well-known with ”Topology optimization”.
As the vehicle chassis is the link between the cabin, engine, transmission and axles, it has a great
importance in the construction of vehicle. For the development of production, engineering companies have
high costs due to the time it takes to get a better product, and it is very difficult to develop and design
a product with the lightweight of the material that suits to the application. The stringer chassis is one of
the most important items of the vehicle because that is where it supports all parts of the structure in the
propellant vehicle.
Actually, the United States, Denmark, China, Japan, etc., use the optimization technology in the con-
struction of their products, reducing the weight, size and final cost of production. This paper search to
identify such optimization technology, and applies it in the analysis of a chassis (trucks or buses), comparing
some commercial software for this analysis. It will be used for comparison some softwares that have some op-
timization type incorporated such as Optistruct (Altair), SolidWorks (Dassault Systemes) with ParetoWorks
(Sciart), ANSYS and Spaceclaim (ESSS) with Virtual PYXIS (Virtual CAE).
After this comparison, will be creat in a next article a new software through of the simplex algorithm
theory, which has the linprog (a routine MATLAB), specific software for weight reduction chassis. By
experimental knowledge, this technology has never been used in Brazil specific in the automotive industry.
Nowadays, there are at least five broad classes of distinct optimization technology. They are: Structural
Optimization,Parameter Optimization, Multidisciplinary Optimization (MDO), Multi-objective or Pareto
Optimization and Robustness and Reliability Optimization. These are broad classes commonly used for
many applications in industry and academy. Depending of the nature of the design problem is used one or
other optimization broad classes.
So, the proposal of this article find to identify the problems of the product engineers, searching to reduce
material for better distribution of weight x power ratio, with the use of the optimization topology. The
results will contribute to a new application in academic and industrial use.

Keywords: Topology Optimization, ParetoWorks, Optistruct, Virtual PYXIS, ANSYS, Spaceclaim.

1 Introduction
Almost of the companies of the vehicle chassis manufacturers try to reduce the weight of their structures. The
weight reduction occurs as an end result, with several positive factors such as decrease in vehicle consumption,
possible higher of load in the axles, reducing weight and components of the front and rear axles, the possibility
of lowering the tread, allowing best tire costs, etc. Study or work related to the optimization of use to solve the
variables found in a design of a stringer chassis.
There are many technical literatures of engineering, however, specifically the optimization method is cur-
rent, that is, there are not large developments in the project area in the national companies of the vehicle
manufacturer. The study is against this problem, and aims to establish the hole and positioning not only by
computer-aided engineering (CAE) [1] systems, but also by optimization for the analysis of chassis and com-
ponents manufacturing. The proposal would be to identify an existing chassis market to understand the forces
acting on the beam in relation to the permissible total gross weight (PBT), especially the torsional tension
forces in the element, check the current drilling plane of the stringer and through topology optimization method
know with TOM, propose a new drilling plan and cuts to this stringer as a result of the developed software.

2 Literature Review
2.1 Introduction and basic concepts in optimization
There are at least five broad classes [2] are many important for developing in industry. They are classified
as (Figure 1):

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 Figure 1: Optmization broad classes.
• Structural optimization
Structural optimization [3] is an optimization of a structure’s shape [4], size, topology, topometry or
topography. Topology optimization is only one kind of structural optimization. Size optimization consists
of modifying properties of structural elements. Shape optimization is to minimize volume surface shape of
a 2D or 3D solid. Topology optimization is the form for the reducing material with density, homogenization
[5] or level-set methods. Topography and topometry optimization, like are applicable only to 2D or shell
elements.
• Parameter optimization
Parameter optimization find to solve problems such as minimization of a specified objective function over
a defined data set.
• Multidisciplinary optimization (MDO)
Multidisciplinary optimization (MDO) is the actual area that involves many disciplines, fluid, thermal,
acoustic, NVH, multibody dynamics, crashworthiness, etc.
• Multi-objective or Pareto Optimization
Multi-objective or Pareto optimization is a method for numerically defined the Pareto frontier with base
on exogenous factors, with decision for human and not by computer model only.
• Robustness and reability optimization
Robustness and reliability optimization are methods for control of the measured in terms of a mean value
and its variance.

2.2 Introduction topology optimization

The optimization has become a major theme in the aviation areas, where the reduction in weight of the
material was closely linked to the cost they could be manufactured. The method is know with TOM [6] [4] [7]
[8] [9].
There are various methods used to perform topology optimization: Homogenization, Solid Isotropic mate-
rial without or with penalization (SIMP), Continuous, level-set, Evolutionary Structural Optimization (ESO),
Topological derivatives, etc. There are already some software existing for optimization, but there is a great
find for high-performance processing and calculation speed. The main purpose of this article is to analyse the
existence of software through TOM with application in automotive industry.
At the end of the 1980s, several studies of the optimization in universities and also in the airline industry
has had a good rise of the model, however, [4] proposed the application in optimization of continuous structures
with this possibility was a step for obtaining optimal structures have been carried out for many applications. In
the method, there is the possibility to find the so-called empty positions (positions 0) or full positions (positions
1), (Figure 2).
Topology optimization is a computational method for structural optimization. The method lets you set the
optimal topology structures, with the distribution of material within a project area, aimed at the removal or
placement of the material at each point of the domain, which can minimize (or maximize) the objective function

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specified. The method consists of collecting data, to define the function objective to find a maximum deflection,
minimum mass, maximum hardness and others. Through these data and of the function objective is made
optimization problem formulation.

Figure 2: Principle topology optimization[10].

Following define the objective function, and adopt a process such as minimizing the function. It is made
of a process function interactions, and each interaction, a further reduction rate is checked converging the
framework for an optimal solution. Of course for the number of interactions is reduced, we have a large number
of calculations and should adopt such restrictions for the role. The TOM can involve several variables and
search the optimal distribution of material within a project area, it removes and adds material on the fixed area
in order to tend an objective function. Studies involving the current TOM are based on heat transfer, fluid
flow or vibrations, continuous structures. Denmark and Germany, [11] since 1988, there are several studies on
topology optimization.
In Brazil the studies began by the year 2000 at USP (Universidade de São Paulo), and there are currently
large studies in Brazilian universities, UFRGS, PUC-RIO, UFRJ, UFSCAR, UNICAMP, UFABC, etc.

2.3 Mathematics Programming – Approach Simplex

One kind of optimization approach stemmed Linear Programming, formulated also for the use of non-linear
functions is the simplex method. It was developed by Dantzig [12] thus allowing the solution of linear program-
ming problems more efficiently. MATLAB [13] has a routine that solves linear problems, called LINPROG [14].
This routine is designed to help programmers in linear programming calculation because it is a robust program
and widely used in solving engineering problems.

2.4 Criteria for design and manufacture of chassis

The product engineers in Brazil now use CAE, method to analyze continuous structures using software such
as Patran (Pre-processor) and Nastran (processor) and others. The chassis is specified exclusively for the vehicle
to some improvements with respect to resistance aspects, comfort, handling characteristics and processing load.
The chassis is based on the harmony of some aspects of the body intended, planned operating conditions and
type of transport. The chassis is designed to absorb contact on-chassis bodies in various applications such as
waste collector car, freight car truck, road freight transport car, etc., as shown in Figure 3.

Figure 3: Bodies kind applied in the chassis [15].

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 Chassis settings depend on the type or model of equipment, ranging from 4x2, i.e. with 4-wheel contact with
the ground, but with traction on 2 wheels, through 4x4, 6x2, 6x6, 8x2 or 8x4. Some other conditions chassis
configuration can be designed for special equipment, see Figure 4.

Figure 4: Chassi 4x4 [15].

Most of the implements made by coach builders requires diverse dimensions of distance between centers.
The distance between axes is the distance from front axle to rear axle. This is due to the fact that vehicle man-
ufacturers industries has in its sales catalog just a few standardized measures of wheelbase due to minimization
of cost of their manufacturing process. This demand for diverse dimension means that there is change in the
positioning of the rear axle changing holes in the chassis beam when they are not defined by the manufacturer,
(Figure 5). Also for this fact is important that engineers know the detail stringer chassis applied to the vehicle.

Figure 5: Shortening or lengthening t0 wheelbase [16].

The shortening of the chassis is very harmful to the vehicle due to the cut promoted under the chassis in
tractor and dump trucks without sub-frame that isn’t recommended by the manufacturer. The drilling or re-
moval of material in the chassis is one of the most important elements regarding the application of effectiveness.
A fact that not is recommended by vehicle manufacturers is the perforation of the tab stringer, it is these flaps
have the highest stresses in the chassis beam, which can cause rupture around the punched holes, (Figure 6).
Technically one should therefore examine the drilling and removal of material wherever possible using the soul
of the C profile to the removal of materials.

Figure 6: Rules and drilling conditions in the chassis. Unit:mm [17].

The chassis manufacturer predicting the problem originate in relation drilling of a stringer, it recommends
by designers that whenever possible may be used the standard pre-drilled holes in the structure, however if it
is making new holes are adopt as Figure 7 for drilling (Standard norm in accordance with 2007/46/EC.) [18].

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Where the letter A shows the minimum distance between the orifice and the flange delimiting this dimension
should be three times the hole diameter greater than 40 mm, since the dimension B should also be three times
the diameter but larger than 50 mm. The manufacturer sets the hole between the front axle and the rear axle
must be maximum 30 mm.

Figure 7: Standard allowed drilling in the stringer [17].

As much as this pattern drilling stringer was adapted, there is always a doubt whether that point of the
stringer may be holed or not by the body builders, without this critically affects the structure of the stringer.
This question will be found in the expected results of this work.

3 Technical background
The constant difficulty of design engineers who dimensioning bodies on chassis and are faced with excess
weight on the axles of the vehicle by limiting the load is considerable. In order to minimize these impacts, a
proposal that aims to demonstrate the use of topology optimization method for the minimization of specific
material for the construction of vehicle stringer will be prepared. Demonstrate through literature review that
the topology optimization is one of the best methods for analysis of rigid structures that may suffer some
deformation, for it will be used this method to the study. This method can be studied in the future and to
be applied to other parts of the vehicle as the cabin, and drive powertrain, body, etc. It will be mathemati-
cally demonstrated the topological optimization method for this application, with parallel use of HyperWorks
software company, which has a topology optimization analysis module called OptiStruct [19] and also with the
software Solidworks [20] with add-in ParetoWorks[21] [22] and also ANSYS [23] with add-in Virtual PYXIS
[24]. All the analysis will be done in this module. Later analysis of the model will be compared with results
CAE system, will can be demonstrated the effectiveness of TOM and proposed the creation of a software via
LINPROG routine (MATLAB), used by the Simplex method.

4 Methodology
The project engineering companies present developments in various segments. In Brazil there are still few
companies searching to meet the needs of customers for product development through the TOM. Thus, the
subject of study can be presented as follows: ”Topology optimization vehicle chassis: Software applied to opti-
mization trucks and buses chassis stringer in automotive industry”. The work aims to make a contribution to
the area in question in the context of proposing a structure for tasks or activities cycles, for carrying out the
TOM applied to the car chassis product, causing the project to become profitable, with low density material,
etc. It is useful, therefore, that the knowledge gained through this work, you may cause the reader to under-
stand what is a structure built through a methodology, which may be not only specific activities in question,
but some idea suggested by one or through the relationship of these. The concepts developed in this area search
to understand the structure of tasks for the validation of a product through the TOM, and through this search
solutions so there is a demystification of the difficulty of using CAE systems by the designers of engineering
companies. To achieve the objectives should be a study of a car chassis through OptiStruct, ParetoWorks and
Virtual PYXIS module, and through linear programming functions of mathematical model. The purpose of the
methodology is to help us understand the incomprehensible, in the broadest terms, not only the products of sci-
entific research, but the process itself, therefore, any successful scientific research implies certain methodological
consciousness Kaplan [25]. The path that has been founding for scientific methodology is given in accordance
with the execution of studies of reference bibliographies that exist with regard to similar cases, and from these
studies, measure, or quantify the studies regarding the application of the TOM in engineering companies. This
run will search first set the foundation of the what is this, and how to work the engineering companies in the
various organizations of this medium in Brazil, with respect to product development through the TOM from
this definition will be explored the types of tasks that have been through TOM of the study and after this
was related to the study manufacturing a prototype vehicle chassis. Was adopted a methodology that can be

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structured by the sequence of steps shown graphically in Figure 8.

Figure 8: Search Structure. Source: The author.

Through the technical proposal initially, a literature reference will be finding, focusing on areas of Topology
Optimization, Structural Mechanics and Manufacturing Processes, (Figure 9). Shall be deemed these areas
because they are more associated with delimitation of the subject. The concepts addressed these three areas
include the interests of research.

Figure 9: Area of research interest. Source: The author

Thus, a search of the bibliography was done, getting up the main items related to the research question (sub-
ject matter). It will also be defined as aspects of product features to structure the study. As the main technique
to achieve the objectives of this study, had used the documentary research, which according to Godoy,[26], is
the examination a lot of materials, which have not yet received an analytical treatment, or may be re-examined,
searching for new interpretations or complementary. This documentary part will be generated through the
results of OptiStruct, ParetoWorks and Virtual PYXIS module.

5 Numerical Implementation of the topology optmization algorithm

The code of the topology optimization algorithm is implemented in MATLAB using the LINGPROG (a
routine of the MATLAB). At each iteration of the topology optimization algorithm, a structural analysis is
carried out by using Finite Element Method (FEM)[1], to account for the calculation of the output displacement
of the structure. The gradients of the objective function and constraints are calculated. The optimizer generates
a new set of design variables after each iteration and the optimization continues until convergence is achieved
for the objective function.[27]
The PLS solves several linear sub problems sequentially find the solution of the non-linear problem. The
PLS has been applied successfully in Topological optimization in several papers in the literature and is therefore
the method of choice for this job.
Numerical methods require the continued dominance of the structure is discretized. Thus we have, for
example, instead of a continuous distribution density inside the field structure, density values of the elements
composing the field of discretized structure. It is considered as a variable density element which is a continuous
variable, you can take any value within the element. In this work, the domain structure is discretized into finite
elements. The TOM software proposed in this paper can be implemented using the MATLAB programming
language. Figure 10 describes the software algorithm procedure.

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 Figure 10: Flowchart TOM procedure. Source: Adapted: [28]

6 Results
This project is premised development through topology optimization reducing material of a stringer vehicle
chassis (truck and bus) with mathematical model and Optistruct, ParetoWorks and Virtual PYXIS software,
which can be used in the automotive industry, mainly serving design engineers the chassis area vehicle. In
this work we see the confrontation of topological optimization method front of the CAE system in relation
to its better efficiency due to minimization function via an interaction cycle. It made possible the productive
capacity of this material on an industrial scale with a new drilling plan in the chassis beam, and software that can
simulate this plan, because the project has industrial support of Scania companies in Brazil (Chassis builder) and
Lavrita Engineering (construction of several implemented bodies), form of the provision of resources, availability
of information, among others.
6.1 The Stringer Chassis
The stringer chassis is existing in the industry. The model of the truck that receiving the stringer chassis
is Scania P440 CB 4x4. This chassis is made for attending special vehicles with firetrucks, and others, (Figure
11).

Figure 11: Courtesy Lavrita Engenharia [29].

The stringer chassis have many hole for to fix all components of the structure. The designers and engineers
of the Scania finding developing the stringer putting this hole between of the simulation CAE. But not is utilized
TOM for design the holes in stringer. The design of the chassis is accordance with Figure 12.

Figure 12: Stringer Scania P440 CB 4x4 Source: The autor

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6.2 The Loads and constrains
The stringer chassis of the firetruck has the max load of the 100.000N and 6 fixed points in structure . The
material of this structure is LNE 380 that is a carbon steel with the tensile strength limit with 440 MPa, that
is a isotropic material. To see Figure 13.

Figure 13: Loads and constrains of the structure Source: The autor

6.3 Criteria of the analyses CAE and TOM

For to simplified of the analyses we adopt the two-dimensional phase. The formula of the TOM for elements
of the two-dimensional phase is.

6.4 Results of the CAE

The analyses post-processing were make only with structural static, with the Software PartoWorks, ANSYS
and Optistruct. Was observed the max. stress (critery of the Von Misses) ant the max. Displacement, (Figure
14,15 and 16).

Figure 14: ParetoWorks: Maxim Stress Source: The autor

Figure 15: ANSYS: Maxim Stress Source: The autor

Figure 16: OPTISTRUCT: Maxim Stress Source: The autor

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 Figure 17: ParetoWorks: Maxim Displacement Source: The autor

Figure 18: ANSYS: Maxim Displacement Source: The autor

Figure 19: OPTISTRUCT: Maxim Displacement Source: The autor

Between this results we have a comparative table. To see table 1.

Table 1: Results numerical.

Software No .Elements Maxim Stress(MPa) Maxim Displacement(mm)

ParetoWorks 1000 470.000 1900
ANSYS 986 254.920 0.565
OPTISTRUCT 1224 385.100 1.661

Is possible to observe that the maxim stress is approximately similar between the software ANSYS and
software OPTISTRUCT. This fact it happens because the type of the analysis is by OC (Optimization criteria)
with material law SIMP, and without penalization of the material. Already ParetoWorks the TOM is by Pareto.
Is other form of the analysis.

6.5 Results of the analys TOM

Was adopted by criteria of the designer, the condition of the minimization of the volume until 70 percent of
the structure volume. This criteria was adopted because before was analysed of the structure per maximizing
stiffness, and this other criteria the reduction was between 50-55 percent, but with criteria, the structure was
separated in more that two parts. Then, this criteria wasn’t adopted. Now how stayed the structure with
volume minimization until 70 percent (Figure 20,21,22).

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 Figure 20: PARETOWORKS: TOM. Source: The autor

Figure 21: VIRTUAL PYXIS: TOM Source: The autor

Figure 22: OPTISTRUCT: TOM. Source: The autor

6.6 Superposition with the stringer chassis existent

In accordance with the propose this article, is possible to put the design of the TOM in stringer chassis
existent, and after remove the holes existent where not is correct to put holes. We have analysis different
between ParetoWorks, Virtual PYXIS and Optistruct, was analysed the three cases. This Figure 23 has the
first case with ParetoWorks, In Figure 24 has the second case with Virtual PYXIS or Optistruct. In Figure 25
is third case. In Figure 26, 27 and 28 is propose new stringer chassis in the three cases.

Figure 23: PARETOWORKS: Superposition with Stringer chassis. Source: The autor

Figure 24: VIRTUAL PYXIS: Superposition with Stringer chassis. Source: The autor

Figure 25: OPTISTRUCT: Superposition with Stringer chassis Source: The autor

6.7 New Stringer chassis

This is the final result with the propose. The designers and engineers of the automotive industry has a new
form for to know if is possible to hole in anywhere position in stringer chassis, (Figure 26, 27 and 28).

Figure 26: PARETOWORKS: New stringer chassis. Source: The autor

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 Figure 27: VIRTUAL PYXIS: New Stringer chassi. Source: The autor

Figure 28: OPTISTRUCT: New Stringer chassi. Source: The autor

6.8 Comparing between software

The three software were analysed with same loads and constrains and materials. ParetoWorks have problems
for processes up of 10.000 elements in this application , but with 1.000 elements was the faster for configuration of
the conditions of the boundary. However by little structures is possible configure more than 1.000.000 elements
easily. Virtual PYXIS is very good by TOM, have many functions, and by to work with the solver (ANSYS) is
faster by to solver problem. Optistruct is a good software that together with the software Hypermesh is easy
configure many options of the meshes. Then is possible to generate a mesh with good quality.
The different results for a new stringer chassis is normal, because each software has a specific algorithm. The
optimization with Virtual PYXIS for this application was the best (chassis with large up 6.000mm), because
only reduce holes in parts really possible in practice in accordance with the draftsman of the structure. The
OC is material law SIMP without penalization was the more possible to do a good application. However the
software ParetoWorks and Optistruct can be tested in many others parts of the vehicle, then all software are
possibles by to use for TOM.

7 Conclusions
It is seen that the optimization area is new and that we should look for it to reduce costs into the automotive
industry. This article aims to research the bibliographic proposed for comparison, and promove the possibility
of the developing an specific algorithm for optimization of the holes in stringer chassis, the theme is possible
developing in other future article.
How possibility for developing this article it is proposes two studies: developing the reducing of the holes in
stringer chassis with structural analysis of the three-dimensional fase and developing news analysis for stringer
chassis as dynamic structural, vibrations, and others areas.

8 Acknowledgements
The present study was supported by Altair Brazil (Mr. Valdir Cardoso); ESSS ANSYS (Mrs. Mariana
Buchner Linard); Virtual PYXIS Brazil (Mr. Leandro Garbin and Mr. Paulo Nigro); Sciart (Mr. Praveen
Yadav); University of Winconsin (Dr. Krishnan Suresh and MBA Liz Christenbury), Lavrita Engenharia (Mr.
Wilson Molina and Mr. Roberto Molina), and Scania (Mr. Hugo) and also Mr. Dr. Cicero Ribeiro de Lima
(UFABC-SP) by the incentive developments in area of the topology optimization and MSc Kelly Cristina de
Lira Lixandrão (UFABC-SP), my wife by incentive and comprehension. To all colleagues a big thanks.

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