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Experimental and numerical investigation of crashworthiness performance for optimal automobile structures using response surface methodology and oppositional based learning differential evolution algorithm

  • Ahmet Yildirim

    Ahmet Yildirim received his Bachelor’s degree in Mechanical Engineering from Uludağ University, Turkey, in 2010, and his Master’s degree in Mechanical Engineering from the Bursa Technical University, Turkey, in 2017. He is an R&D and design engineer in Toksan R&D Centre, Bursa, Turkey.

    , Emre Demirci

    Dr. Emre Demirci is an Assistant Professor in the Department of Mechanical Engineering, Bursa Technical University, Bursa, Turkey. His major research interests include reliability based design optimization, vehicle crashworthiness, finite element analysis, automotive materials and additive manufacturing. He is currently director of the BTU Automotive Research and Application Center.

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    , Selçuk Karagöz

    Dr. Selçuk Karagöz is an Assistant Professor in the Department of Mechanical Engineering, Bursa Technical University, Bursa, Turkey. His research interests include sheet metal forming, vehicle crashworthiness and 3D printing.

    , Şevket Özcan

    Şevket Özcan received his Bachelor’s and Master degrees in Mechanical Engineering from Uludağ University, Turkey, in 2010 and 2017, respectively. He worked as a structural analysis engineer in Toksan R&D Centre, Turkey.

    and Ali Riza Yildiz

    Dr. Ali Riza Yildiz is a Professor in the Department of Mechanical Engineering, Bursa Uludağ University, Bursa, Turkey. His research interests are the finite element analysis of structural components, lightweight design, vehicle design, vehicle crashworthiness, shape and topology optimization of vehicle components, meta-heuristic optimization techniques and additive manufacturing.

Published/Copyright: March 8, 2023
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Abstract

In this study, experimental and numerical crash analyses are carried out to reach an optimum bumper beam and energy absorber design for a passenger car. Design parameters have been created to determine the most crash-efficient bumper beam and energy absorber models. The models that are formed by using Taguchi tables are subjected to crash analysis, and the responses are obtained to find an optimal design. Response surface methodology is used to approximate the structural responses in crash analysis, and the optimum bumper beam and energy absorber models are obtained by the differential evolution algorithm. The optimum model is subjected to crash analysis in the Hyperform software without considering the sheet metal forming effect. Besides, the model is analyzed by incorporating forming history into the crash analysis. As a result of the numerical analysis, a new energy absorber and bumper beam model with the better crash performance and weight reduction are obtained.


Corresponding author: Emre Demirci, Department of Mechanical Engineering, Bursa Technical University, Bursa, 16310, Türkiye, E-mail:

Award Identifier / Grant number: 0302.STZ.2013-2

About the authors

Ahmet Yildirim

Ahmet Yildirim received his Bachelor’s degree in Mechanical Engineering from Uludağ University, Turkey, in 2010, and his Master’s degree in Mechanical Engineering from the Bursa Technical University, Turkey, in 2017. He is an R&D and design engineer in Toksan R&D Centre, Bursa, Turkey.

Emre Demirci

Dr. Emre Demirci is an Assistant Professor in the Department of Mechanical Engineering, Bursa Technical University, Bursa, Turkey. His major research interests include reliability based design optimization, vehicle crashworthiness, finite element analysis, automotive materials and additive manufacturing. He is currently director of the BTU Automotive Research and Application Center.

Selçuk Karagöz

Dr. Selçuk Karagöz is an Assistant Professor in the Department of Mechanical Engineering, Bursa Technical University, Bursa, Turkey. His research interests include sheet metal forming, vehicle crashworthiness and 3D printing.

Şevket Özcan

Şevket Özcan received his Bachelor’s and Master degrees in Mechanical Engineering from Uludağ University, Turkey, in 2010 and 2017, respectively. He worked as a structural analysis engineer in Toksan R&D Centre, Turkey.

Ali Riza Yildiz

Dr. Ali Riza Yildiz is a Professor in the Department of Mechanical Engineering, Bursa Uludağ University, Bursa, Turkey. His research interests are the finite element analysis of structural components, lightweight design, vehicle design, vehicle crashworthiness, shape and topology optimization of vehicle components, meta-heuristic optimization techniques and additive manufacturing.

  1. Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.

  2. Research funding: This study was funded by the Turkish Ministry of Science, Industry, and Technology, and TOKSAN R&D Centre within the scope of the SAN-TEZ project 0302.STZ.2013–2.

  3. Conflict of interest statement: The authors declare no conflicts of interest regarding this article.

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Published Online: 2023-03-08
Published in Print: 2023-03-28

© 2023 Walter de Gruyter GmbH, Berlin/Boston

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