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<p>Traditional vehicle door panels struggle to meet the increasing demands for lightweighting, safety, and cost efficiency. The emergence of Tailor-welded Blank (TWB) technology enables the integration of multiple materials, enhancing material utilization and design flexibility. However, efficiently determining optimal material configurations remains a challenge. This study proposes a rapid multi-material design method to address this issue, facilitating the efficient conceptual design of high-performance door panels. Specifically, based on the topology optimization results for each stiffness case, a novel design of a Hybrid Material Tailor-welded Structure is proposed for the inner door panels, which makes it applicable to most of the conceptual design configurations. A hybrid multilevel multi-criteria optimization decision-making system is proposed. The method integrates the VlseKriterijumska Optimizacija I Kompromisno Resenje method, the Multi-objective Grey Wolf Optimization (MOGWO) algorithm to find the optimal zonal material combinations and the optimal parameter solutions for the inner door panels. Then the application effects of the Multi-objective Particle Swarm Optimization and Non-dominated Sorting Genetic Algorithm II, and MOGWO are compared to perform the structural multi-material optimization. The results show that the optimized multi-material door achieves a weight reduction of 4.2% in terms of lightweighting, and improves the rest of the performance indicators. Additionally, the proposed conceptual design approach reduces the computational cost by at least 70% and significantly improves the computational efficiency compared to traditional optimization methods. The study provides important ideas and directions for the development of TWB technology and the advancement of automotive manufacturing.</p>

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Conceptual design and optimization of multi-material inner door panels for vehicle

  • 期刊论文

  • 发表日期：

    2025年10月11日

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  • Danqi Wang,
  • Wengang Deng,
  • Fang Wang,
  • Qiqi Li,
  • Honghao Zhang,
  • Lin Hu

摘要

Traditional vehicle door panels struggle to meet the increasing demands for lightweighting, safety, and cost efficiency. The emergence of Tailor-welded Blank (TWB) technology enables the integration of multiple materials, enhancing material utilization and design flexibility. However, efficiently determining optimal material configurations remains a challenge. This study proposes a rapid multi-material design method to address this issue, facilitating the efficient conceptual design of high-performance door panels. Specifically, based on the topology optimization results for each stiffness case, a novel design of a Hybrid Material Tailor-welded Structure is proposed for the inner door panels, which makes it applicable to most of the conceptual design configurations. A hybrid multilevel multi-criteria optimization decision-making system is proposed. The method integrates the VlseKriterijumska Optimizacija I Kompromisno Resenje method, the Multi-objective Grey Wolf Optimization (MOGWO) algorithm to find the optimal zonal material combinations and the optimal parameter solutions for the inner door panels. Then the application effects of the Multi-objective Particle Swarm Optimization and Non-dominated Sorting Genetic Algorithm II, and MOGWO are compared to perform the structural multi-material optimization. The results show that the optimized multi-material door achieves a weight reduction of 4.2% in terms of lightweighting, and improves the rest of the performance indicators. Additionally, the proposed conceptual design approach reduces the computational cost by at least 70% and significantly improves the computational efficiency compared to traditional optimization methods. The study provides important ideas and directions for the development of TWB technology and the advancement of automotive manufacturing.