This paper presents an extension of our previous work on decomposition-based assembly synthesis for structural stiffness, where the 3D finite element model of a vehicle body-in-white (BIW) is optimally decomposed into a set of components considering the stiffness of the assembled structure under given loading conditions, as well as the manufacturability and assembleability of components. Two case studies, each focusing on the decomposition of a different portion of a BIW, are discussed. In the first case study, the side frame is decomposed for the minimum distortion of front door frame geometry under global bending, In the second case study, the side/floor frame and floor panels are decomposed for the minimum floor deflections under global bending. In each case study, multi-objective genetic algorithm with graph-based crossover, combined with FEM analyses, is used to obtain Pareto optimal solutions. Representative designs are selected from the Pareto front and trade-offs among stiffness, manufacturability, and assembleability are discussed.
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