DESIGNING AN INNOVATIVE MODULAR PLATFORM FOR SPORTS CARS USING THE GENERATIVE DESIGN METHOD

This paper introduction was written based on the 'DESIGNING AN INNOVATIVE MODULAR PLATFORM FOR SPORTS CARS USING THE GENERATIVE DESIGN METHOD' published by 'Università di Bologna'.

1. Overview:

Title: DESIGNING AN INNOVATIVE MODULAR PLATFORM FOR SPORTS CARS USING THE GENERATIVE DESIGN METHOD
Author: Merve Sali
Publication Year: 2024
Publishing Journal/Academic Society: DOTTORATO DI RICERCA IN MECCANICA E SCIENZE AVANZATE DELL'INGEGNERIA, Università di Bologna
Keywords: Not explicitly listed in the provided document. Keywords can be inferred from the title and abstract as: Modular Platform, Sports Cars, Generative Design Method, Automotive Chassis, Lightweight Design, Agile Method, Scrum.

2. Abstracts

Traditional methods, where chassis components are tailored for each vehicle type, lack flexibility and efficiency. The concept of current modular platforms, allows the reuse of components across different models, reducing production costs and enhancing adaptability. But, in current situation these solutions are not common in sports cars segment. The research delves into the challenges and opportunities posed by modular platforms in the context of sports cars, highlighting their potential impact on driving dynamics, design aesthetics, and future innovations. The project focuses on a modular platform approach, providing diversity while maintaining a standardized design sections, emphasizing interchangeability of components besides flexibility, using cutting-edge design methods. This study addresses to create a modular platform suitable for different drivetrain and powertrain configurations, with iterative sprints targeting lightweight and high-stiffness designs by using generative design method. In addition to improving design outcomes, efforts have been made to enhance creativity by employing the steps of the generative design method within the existing workflow (IDeS), and collaboration with the Agile method variant, Scrum, has been established to filter the results, which is crucial for project development. Moreover, it has been applied to an alternative modular platform created with new parts obtained through the generative design application. The results obtained have been evaluated in terms of the model's mechanical properties. These new parts are not only geometrically more efficient but also capable of yielding the same mechanical results even when different materials are used. Numerical results of simulations are compared for the final assemblies created with generated components (Part 1, Part 3, and Part 4) and with initial components. In particular, it has been demonstrated that, by employing the generative design method, equivalent strength values can be achieved by using aluminium alloy instead of steel alloy for the component of Part 3 (Outcome 7). Torsion and bending stiffness tests on each model have been performed before and after generative design process. The parts defined to generate decided with crash tests on rear-mid and front modular platform layouts separately. The results have been compared and it has found that stress distributions are similar which means the parts that we have generated are sufficient in new design such as shapes, weight, and mechanical properties.

3. Research Background:

Background of the Research Topic:

Traditional chassis design methods for vehicles lack flexibility and efficiency because components are tailored for each vehicle type. Current modular platforms offer component reuse across models, reducing production costs and improving adaptability. However, these solutions are uncommon in the sports car segment. This research addresses the challenges and opportunities of modular platforms in sports cars, considering their impact on driving dynamics, design aesthetics, and innovation. The project aims to create a modular platform for sports cars, emphasizing diversity, standardized design, component interchangeability, and flexibility using cutting-edge design methods.

Status of Existing Research:

Existing research acknowledges the benefits of modular platforms in the automotive industry, including cost reduction and increased flexibility (Florea et al., 2016; Lampón et al., 2015). Literature review highlights the evolution of platform strategies, from shared platforms pioneered by Mitsubishi (Cusumano & Nobeoka, 1998) to the standardization efforts by PSA Group (Holweg, 2008; Patchong et al., 2003). Research also explores the application of generative design and additive manufacturing for lightweight automotive components (Junk & Rothe, 2022; Fenoon et al., 2021; Dalpadulo et al., 2020), indicating a trend towards innovative design and material utilization in chassis development.

Necessity of the Research:

The research is necessary due to the limited application of modular platforms in the sports car segment despite their potential benefits. The increasing demand for flexibility, efficiency, and adaptability in automotive manufacturing, coupled with the need for lightweight designs and sustainable practices, necessitates exploring innovative approaches like generative design for modular sports car platforms. Furthermore, the need to address climate change and reduce CO2 emissions (European Parliament and the Council of the European Union, 2019) drives the automotive industry towards modular and sustainable solutions.

4. Research Purpose and Research Questions:

Research Purpose:

This study addresses to create a modular platform suitable for different drivetrain and powertrain configurations, with iterative sprints targeting lightweight and high-stiffness designs by using generative design method. In addition to improving design outcomes, efforts have been made to enhance creativity by employing the steps of the generative design method within the existing workflow (IDeS), and collaboration with the Agile method variant, Scrum, has been established to filter the results, which is crucial for project development.

Key Research:

Creation of a modular platform for sports cars adaptable to different drivetrain and powertrain configurations.
Application of generative design method to achieve lightweight and high-stiffness designs.
Integration of generative design within the Industrial Design Structure (IDeS) workflow.
Implementation of Scrum methodology to manage and filter generative design outputs.
Evaluation of the modular platform's mechanical properties and performance.

Research Hypotheses:

The paper does not explicitly state research hypotheses. However, based on the research purpose and key research questions, the implicit hypotheses are:

Generative design method can create geometrically efficient and lightweight components for a modular sports car platform.
A modular platform designed with generative design can achieve equivalent or improved mechanical properties compared to platforms designed with traditional methods.
Integrating Scrum methodology with IDeS workflow and generative design can enhance the efficiency and creativity of the design process for modular platforms.
Using aluminium alloy in generatively designed components can achieve equivalent strength to steel alloy components while reducing weight.

5. Research Methodology

Research Design:

The research employs a design-based research approach, focusing on the development of an innovative modular platform using generative design. It integrates the Industrial Design Structure (IDeS) workflow with Scrum methodology and generative design techniques. The design process is iterative, involving sprints and adaptations based on analysis and testing.

Data Collection Method:

Data collection methods are not explicitly detailed in this summary, but can be inferred as:

Literature review: To understand existing research on modular platforms, generative design, and automotive chassis design.
Market analysis data: To understand market trends, customer requirements, and competitor analysis.
Simulation data: Numerical results from simulations (torsion, bending, crash tests) to evaluate mechanical properties.
Expert interviews: Break-up of the profiles of industry experts are shown in Figure 3.1.

Analysis Method:

Quality Function Deployment (QFD): To analyze customer requirements and translate them into design parameters.
Dependence / Independence Matrix and Relative importance matrix: To prioritize customer requirements.
Benchmarking: To compare existing sports car models and identify design parameters.
Finite Element Analysis (FEA): Using SolidWorks Simulation to perform mechanical stress analyses (torsional stiffness, bending stiffness, frontal impact analysis) and evaluate the performance of the modular platform and generatively designed components.
Comparative analysis: Comparing simulation results of initial and generatively designed components, and platforms with different configurations and materials.

Research Subjects and Scope:

Research Subjects: Design and analysis of a modular platform for sports cars. Generatively designed components for engine compartment (Part 1), cockpit underbody (Part 3), and electric motor compartment (Part 4).
Research Scope: Focuses on the structural design and mechanical performance of the modular platform, particularly its chassis components. The styling and broader vehicle development aspects are also considered but are secondary to the structural and modular design aspects. The material scope is primarily steel and aluminium alloys.

6. Main Research Results:

Key Research Results:

Generative design method was successfully applied to create lightweight components for the modular platform (Part 1, Part 3, Part 4).
Generatively designed components using aluminium alloy achieved equivalent strength values to initial steel alloy components, with significant weight reduction, particularly for Part 3 (Outcome 7).
Torsion and bending stiffness tests were performed and compared for initial and generatively designed modular platforms, demonstrating the viability of the new designs.
A new Scrum workflow model integrated with generative design method and IDeS workflow was developed and applied.
The modular platform design allows for adaptability to different engine layouts (rear-mid and front engine) and powertrain configurations.

Analysis of presented data:

Torsional Stiffness: Torsional stiffness values for both initial and generatively designed platforms are within a comparable range, although slightly lower for the generatively designed rear-mid engine platform (9179.317 Nm/deg) compared to the initial rear-mid engine platform (9705.0857 Nm/deg).
Bending Stiffness: Bending stiffness values are also comparable between initial and generatively designed platforms, with the generatively designed rear-mid platform showing a slightly lower value (21773.6 Nm/deg) than the initial rear-mid platform (25786.02 Nm/deg).
Mass Reduction: Generative design and aluminium alloy usage resulted in significant mass reduction in components (Table 3.14), especially for Part 3, where aluminium alloy Outcome 7 achieved a mass of 3.932 kg compared to the initial steel alloy part.
Stress Distribution: Stress distribution analysis indicated that maximum stress locations are similar in both initial and generatively designed platforms, primarily at connection points and areas of load concentration.

Figure Name List:

Figure 3.17: Plug-in series / Parallel hybrid electric vehicle configuration (Emadi et al., 2008;
Turker et al., 2010) — Figure 3.17: Plug-in series / Parallel hybrid electric vehicle configuration (Emadi et al., 2008; Turker et al., 2010)

Figure 3.20: Parts produced through extrusion (Ferrari 488 Spider, n.d.)

Figure 3.22: Sandwich structured composite application in automotive sub-frame (Czerwinski,
2021) — Figure 3.22: Sandwich structured composite application in automotive sub-frame (Czerwinski, 2021)

Figure 3.26: Subaru (SGP) modular platform

Figure 3.28: BMW (CLAR) modular platform

Figure 3.36: V12 Engine for longitudinal position

Figure 3.39: Battery positioning on modular platform

Figure 3.65: Impact test settings for rear-mid modular platform

Figure 3.82: Modular platform and final design assembly

Figure 3.92: Modular platform for front engine

Figure 1.1: Industrial Design Structure
Figure 3.1: Break-up of the profiles of industry experts
Figure 3.2: The market size of the Automotive Chassis in the Asia Pacific, 2019-2030(USD Billion)
Figure 3.3: Global automotive chassis market share by chassis type, 2022
Figure 3.4: House of quality template
Figure 3.5: QFD- Six Questions
Figure 3.6: Dependence / Independence matrix
Figure 3.7: Relative importance matrix
Figure 3.8: What-How matrix
Figure 3.9: Front Engine layouts with different drivetrain configurations
Figure 3.10: Front Engine layout with all wheel drive configuration
Figure 3.11: Rear Engine layouts with different drivetrain configurations
Figure 3.12: Series HEV configuration
Figure 3.13: Parallel hybrid powertrain configuration
Figure 3.14. Series-Parallel split hybrid powertrain configuration
Figure 3.15: Plug-in series hybrid electric vehicle configuration
Figure 3.16: Plug-in parallel hybrid electric vehicle configuration
Figure 3.17: Plug-in series / Parallel hybrid electric vehicle configuration
Figure 3.18: Generative design iterative process example
Figure 3.19: Example of CAD and generated module used model
Figure 3.20: Parts produced through extrusion
Figure 3.21: The relationship between ultimate tensile strength and total elongation in traditional high-strength steels
Figure 3.22: Sandwich structured composite application in automotive sub-frame
Figure 3.23: PSA Common modular platform
Figure 3.24: Volkswagen MQB modular platform
Figure 3.25: Toyota (TNGA) modular platform
Figure 3.26: Subaru (SGP) modular platform
Figure 3.27: Renault-Nissan CMF modular platform
Figure 3.28: BMW (CLAR) modular platform
Figure 3.29: Modular vehicle platform
Figure 3.30: Part 1: Engine compartment dimensions
Figure 3.31: V6 Chevrolet engine for longitudinal position
Figure 3.32: V6 Jaguar engine for longitudinal position
Figure 3.33: V8 Engine for longitudinal position
Figure 3.34: V8 Engine for transverse position
Figure 3.35: V12 Engine for longitudinal positioning with transmission
Figure 3.36: V12 Engine for longitudinal position
Figure 3.37: Dimensional parameters of seat arrangement illustrated on a car
Figure 3.38: Sports car seat dimensions of fit parameters
Figure 3.39: Battery positioning on modular platform
Figure 3.40: Part 2: Passenger zone dimensions
Figure 3.41: Part 3: Assembly with a) Rear-Mid engine configuration b) Front engine configuration
Figure 3.42: Part 3: Cockpit underbody dimensions
Figure 3.43: Part 4: Assembly with double electric motor
Figure 3.44: Part 4: Electric motor compartment dimensions
Figure 3.45: Modular platform design final model and dimensions
Figure 3.46: Forces during the car motion
Figure 3.47: Longitudinal torsion
Figure 3.48: Torsional stiffness load case
Figure 3.49: Vertical bending
Figure 3.50: Bending stiffness load case
Figure 3.51: Lateral bending
Figure 3.52: Horizontal lozenging
Figure 3.53: Boundary conditions on rear-mid modular platform
Figure 3.54. Displacement results of torsional test for rear-mid modular platform
Figure 3.55. Torsional stress distribution of rear-mid modular platform
Figure 3.56: Boundary conditions on front modular platform
Figure 3.57: Displacement results of torsional test for front modular platform
Figure 3.58: Torsional stress distribution of front modular platform
Figure 3.59: Boundary conditions on rear-mid modular platform for bending test
Figure 3.60: Displacement results of bending test for rear-mid modular platform
Figure 3.61: Bending stress distribution results of rear-mid modular platform
Figure 3.62: Boundary conditions on front modular platform for bending test
Figure 3.63: Displacement results of bending test for front modular platform
Figure 3.64: Bending stress distribution results of front modular platform
Figure 3.65: Impact test settings for rear-mid modular platform
Figure 3.66: Impact test results (a) Displacement results, (b) Deformation distribution results
Figure 3.67: Defined sections for part development on Part 3 and Part 4
Figure 3.68: Impact test settings for front modular platform
Figure 3.69: Impact test results (a) Displacement results, (b) Deformation distribution results
Figure 3.70: Defined section for the part development on Part 1
Figure 3.71: Retro design
Figure 3.72: Stone design
Figure 3.73: Natural design inspired from the dorsal lines of the sailfish
Figure 3.74: Natural design
Figure 3.75: Advanced design
Figure 3.76: Representation of the details selected for the final design
Figure 3.77: Final design sketching
Figure 3.78: Blueprint of final sketch
Figure 3.79: Raw design of final sketch
Figure 3.80: Final 3D design
Figure 3.81: Rendered final design
Figure 3.82: Modular platform and final design assembly
Figure 3.83: Scrum process
Figure 3.84: Generative design workflow
Figure 3.85: Comparison of methods a) Sprint steps (Srivastava et al., 2017) b) Generative design process steps
Figure 3.86: New scrum workflow model with generative design method
Figure 3.87: Modified IDeS workflow using Scrum and Generative Design method
Figure 3.88: Volkswagen MQB platform with material details
Figure 3.89: Boundaries of platform sections
Figure 3.90: Exploded view of the modular platform assembly
Figure 3.91: Modular platform for rear-mid engine
Figure 3.92: Modular platform for front engine
Figure 3.93: Bolted joints of the modular platform
Figure 3.94: Areas defined for generative design
Figure 3.95: Boundary conditions of engine compartment (Part1)
Figure 3.96: Boundary conditions of cockpit underbody (Part3)
Figure 3.97: Boundary conditions for electric motor compartment (Part 4)
Figure 3.98: Structural constraints and loads on Part 1
Figure 3.99: Structural constraints and loads on Part 3
Figure 3.100: Structural constraints and loads on Part 4
Figure 3.101: Generative design results steel alloys applied Part 1
Figure 3.102: Generative design results steel alloys applied Part 3
Figure 3.103: Generative design results steel alloys applied Part 4
Figure 3.104: Generative design results aluminium alloys applied Part 1
Figure 3.105: Generative design results aluminium alloys applied Part 3
Figure 3.106: Generative design results aluminium alloys applied Part 4
Figure 3.107: Generative design applied “Ideal Modular Platform”
Figure 3.108: Beam model of ideal modular platform
Figure 3.109: Displacement results of ideal modular platform for rear-mid engine layout
Figure 3.110: Torsional stress distribution of ideal modular platform for rear-mid engine layout
Figure 3.111: Boundary conditions on front ideal modular platform
Figure 3.112: Displacement results of ideal modular platform for front engine layout
Figure 3.113: Torsional stress distribution of ideal modular platform for front engine layout
Figure 3.114: Boundary conditions on rear-mid ideal modular platform for bending test
Figure 3.115: Displacement results of bending test for rear-mid ideal modular platform
Figure 3.116: Bending stress distribution results of rear-mid ideal modular platform
Figure 3.117: Boundary conditions on front ideal modular platform for bending test
Figure 3.118: Displacement results of bending test for front ideal modular platform
Figure 3.119: Bending stress distribution results of front ideal modular platform

7. Conclusion:

Summary of Key Findings:

The study successfully designed a modular platform for sports cars using generative design methods within an adapted IDeS workflow incorporating Scrum. Generative design enabled the creation of lightweight components, particularly when using aluminium alloys, while maintaining or improving mechanical performance. The modular platform is adaptable to different engine layouts and powertrain configurations, demonstrating its versatility. The integration of Scrum methodology facilitated an iterative and efficient design process.

Academic Significance of the Study:

This study contributes to the academic field by demonstrating the effective application of generative design and agile methodologies (Scrum) in automotive chassis design, specifically for modular platforms in sports cars. It provides a detailed methodology for integrating these cutting-edge techniques within a structured design workflow (IDeS). The research also expands the understanding of material selection and optimization in generative design for achieving lightweight and high-performance automotive structures.

Practical Implications:

The practical implications of this study are significant for the automotive industry, particularly for sports car manufacturers. The developed modular platform design offers a viable solution for reducing production costs, enhancing vehicle adaptability, and improving fuel efficiency through lightweighting. The use of generative design and additive manufacturing techniques can lead to more innovative and efficient chassis designs. The integration of Scrum methodology can streamline the product development process, making it more agile and responsive to changing market demands.

Limitations of the Study and Areas for Future Research:

The study is limited by its focus on the lower part of the chassis and beam model simulations, which are simplifications of a full vehicle chassis. The torsional rigidity values obtained are not directly comparable to full chassis values of existing sports cars. Future research should focus on:

Validating the modular platform design through full vehicle simulations and physical prototyping.
Exploring a wider range of materials and manufacturing processes in generative design.
Investigating the integration of generative design with multi-objective optimization for enhanced performance and sustainability.
Further refining the Scrum-IDeS workflow for different automotive design projects and evaluating its broader applicability.
Conducting experimental validation of the mechanical properties of generatively designed components and the modular platform.

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