Crash Analysis and Optimization of Front-End Structure of Formul SAE

Structural crash optimization can find the best balance between the crashworthiness and lightweight performance of the structure. However, structural crash topology optimization is a typical optimization problem of structural nonlinear dynamic response, and it is the most complex optimization problem at present. In this paper, the novel crash optimization is proposed by combining the Equivalent Static Loads Method (ESLM) and Energy Principle (EP). The ESLM is used to transform the complex crash optimization problem into the static optimization problem. The EP is used to calculate the dynamic load factors that can scale the Equivalent static loads (ESLs) and ensure the static optimization problem under ESLs in linear range. Furthermore, the proposed method is used to optimize the frame structure of Formula SAE (Society of Automotive Engineers) under the crash load. Finally, by comparing the structural performance before and after optimization, it is shown that the method can realize the lightweight design of the racing car structure under the premise of ensuring the crashworthiness of the structure, so as to provide an effective method for the structural optimization design of Formula SAE.