Design optimization of automobile welds

This paper presents the design optimization procedure for the automobile welds based on the sizing optimization technique. The purpose is to reduce the number of welds and save the cost, while the rigidity requirements are satisfied. A special element is proposed to model the spot weld by a serial combination of a rigid element and a 3-dimensional elastic element. Through the innovative utilization of optimization techniques, the optimal weld design is obtained. Furthermore, by using different weld reduction constraints to study critical areas, the relationship between the overall rigidity of an automobile body and the quantity of weld is determined. It is concluded that by using appropriate optimization schemes as presented, the quantity of weld of an automobile body can be substantially reduced and cost savings can be achieved. The proposed method can be used as guidance in optimizing existing or new designs of automobile welds.