Optimization of Foam Filled Door Sill for Pure Electric Vehicle

In this work, the optimization values for several double circular tubes filled with foam under dynamic bending loading are compared. The thin-walled tube is frequently used in vehicle construction, especially on the door sill, to reduce impact. Double circular tubes made of the aluminum alloy AA6063 T6 were filled with foam for this numerical study. Structures are modeled and analyzed using the ABAQUS algorithm. Optimization of tubes determined using Non-Dominated Sorting Genetic Algorithm version II (NSGA II). Excellent agreement between the results of the simulation and the empirically validated FE model has been attained. Also, It was found that a double circular tube filled with foam absorbs more energy than one that is empty of foam. Hence, it can be recommended that this structure be used as an energyabsorbing part, such as a door sill, for pure electric vehicles (PEV).