Formulating Structural Design and Analysis Practices Using First Order Analysis

Abstract

This paper addresses the issues encountered in both the conventional and advanced automobile design and analysis method by introducing First Order Analysis (FOA). Conventional method idealizes automobile structure as framework structure connected by beams. Sizing of the beam sections is based on simplified structural of mechanics calculation. Beam idealization is simple but potentially causes design faults, as it does not correspond to panel/surface models appearing in subsequent stages of product development. This problem complicates further due to highly redundant automobile structures whereby closed form solutions are not possible. Fortunately, these issues have been resolved with the application of Finite Element Method (FEM) in the early eighties. FEM has become the 'de facto' numerical tool for solving statically indeterminate structure, which is a characteristic of modern automobile structure. FEM faces greater challenge as each design problem is unique and 'off-the-shelf' FEM software is usually not applicable. Customization of software is inevitable to construct appropriate FE idealization for design and analysis. Design and analysis practices using FOA are therefore being introduced to realize a less complicated and inexpensive tool for design engineer to evaluate behaviour of automobile structure to swiftly estimate "close to right" design. The template formulated by the FOA in this paper is the deployment of the best practices for automobile structures.