Design optimization of the S-frame to improve crashworthiness

In this paper, the S-frames, the front side rail structures of automobile, were investigated for crashworthiness. Various cross-sections including regular polygon, non-convex polygon and multi-cell with inner stiffener sections were investigated in terms of energy absorption of S-frames. It was determined through extensive numerical simulation that a multi-cell S-frame with double vertical internal stiffeners can absorb more energy than the other configurations. Shape optimization was also carried out to improve energy absorption of the S-frame with a rectangular section. The center composite design of experiment and the sequential response surface method (SRSM) were adopted to construct the approximate design sub-problem, which was then solved by the feasible direction method. An innovative double S-frame was obtained from the optimal result. The optimum configuration of the S-frame was crushed numerically and more plastic hinges as well as shear zones were observed during the crush process. The energy absorption efficiency of the structure with the optimal configuration was improved compared to the initial configuration.