In addition to the feasibility analysis, Lukas also wanted to develop a simulation process which can be used more widely, with additional scope for testing stiffness specifications for other vehicle components. He used design-of-experiments methods and finite element simulations to test a variety of rim designs as part of the small overlap crash tests. One of the things Lukas did was to vary the wall thickness in the rim well in search of the ideal combination of parameters for crash performance.
“It was really tricky to get the optimisation tool up and running with the right settings – all the more reason to be pleased with my work because I was able to demonstrate the fundamental feasibility of an optimised rim,” said Lukas. The bachelor’s thesis yielded two optimum solutions – one lighter in weight but lower in rigidity and the other with minimal weight reduction but a higher degree of rigidity. The process also offers a valuable basis for future research, with the potential for further refinement as well as application to more complex problems.
The PSW team was supportive of Lukas throughout the entire assignment. “My supervisor Andreas Hippe was available for consultation on a weekly basis, or even daily if necessary, and colleagues like Stanislav Berditchevski and Stefan Omasreiter helped me when I had questions about internal policies. I also had Michael Roth as a point of contact for organisational matters and a link to the supervising professor,” added Lukas. Having completed his bachelor’s degree, Lukas is now working as a master’s student employee at PSW and is broadening his knowledge of simulation.
