Abstract: A computer-implemented method for optimizing a design of a physical object comprises: obtaining a data representation of the design of the physical object, including a plurality of elements, determining plural element clusters comprising a plurality of elements and estimating a cost model for the physical object. The method determines derivatives of the cost model with respect to a material density of each cluster. At least one analytical derivative of a performance metric for each element is computed. The design is optimized by iteratively performing: varying the material density of at least one element based on the analytical derivative and the estimated derivatives of the cost model, estimating the cost using the cost model based on the data representation with varied material density. The method generates and outputs a signal comprising the optimized data representation in case a termination criterion has been met.

Abstract: A transition structure includes a metallic portion, a fiber portion including a plurality of tows embedded within the metallic portion and extending out from the metallic portion forming a fabric, and a binding material forming a matrix surrounding the fiber portion embedded within the metallic portion. The fiber portion may be attached to or form part of a composite vehicle component. The transition structure may join a metallic component and a composite component. The transition structure may be manufactured by creating first channels within a layer of a metallic substrate, inserting fiber tows into the first channels, placing a first metallic layer over the metallic substrate and the fiber tows, consolidating the metallic layer to the metallic substrate, and binding the fiber tows within a resin. Prior to binding, additional layers of channels and fiber tows may be consolidated onto the first metallic layer.

Abstract: A transition structure includes a metallic portion, a fiber portion including a plurality of tows embedded within the metallic portion and extending out from the metallic portion forming a fabric, and a binding material forming a matrix surrounding the fiber portion embedded within the metallic portion. The fiber portion may be attached to or form part of a composite vehicle component. The transition structure may join a metallic component and a composite component. The transition structure may be manufactured by creating first channels within a layer of a metallic substrate, inserting fiber tows into the first channels, placing a first metallic layer over the metallic substrate and the fiber tows, consolidating the metallic layer to the metallic substrate, and binding the fiber tows within a resin. Prior to binding, additional layers of channels and fiber tows may be consolidated onto the first metallic layer.

Abstract: A transition structure includes a metallic portion, a fiber portion including a plurality of tows embedded within the metallic portion and extending out from the metallic portion forming a fabric, and a binding material forming a matrix surrounding the fiber portion embedded within the metallic portion. The fiber portion may be attached to or form part of a composite vehicle component. The transition structure may join a metallic component and a composite component. The transition structure may be manufactured by creating first channels within a layer of a metallic substrate, inserting fiber tows into the first channels, placing a first metallic layer over the metallic substrate and the fiber tows, consolidating the metallic layer to the metallic substrate, and binding the fiber tows within a resin. Prior to binding, additional layers of channels and fiber tows may be consolidated onto the first metallic layer.

Abstract: A transition structure includes a metallic portion, a fiber portion including a plurality of tows embedded within the metallic portion and extending out from the metallic portion forming a fabric, and a binding material forming a matrix surrounding the fiber portion embedded within the metallic portion. The fiber portion may be attached to or form part of a composite vehicle component. The transition structure may join a metallic component and a composite component. The transition structure may be manufactured by creating first channels within a layer of a metallic substrate, inserting fiber tows into the first channels, placing a first metallic layer over the metallic substrate and the fiber tows, consolidating the metallic layer to the metallic substrate, and binding the fiber tows within a resin. Prior to binding, additional layers of channels and fiber tows may be consolidated onto the first metallic layer.

Abstract: A system, method and software product for modeling spot welds in a finite element analysis is described. The spots welds are represented by beam elements or solid elements in accordance with an indicator flag. The flag may also be specified as the number (e.g., an integer such as 1, 4, 8 or 16) of solid elements in a cluster representing spot weld. The solid elements may include, but not limited to, hexahedron, tetrahedron, and the likes. The number of solid elements and required nodes are generated for each spot weld based on the indicator flag. A table is formed to group the generated solid elements in a cluster together, so that the force and moment resultants of the spot weld can be computed and assembled in a file.

Abstract: A system, method and software product for modeling spot welds in a finite element analysis is described. The spots welds are represented by beam elements or solid elements in accordance with an indicator flag. The flag may also be specified as the number (e.g., an integer such as 1, 4, 8 or 16) of solid elements in a cluster representing spot weld. The solid elements may include, but not limited to, hexahedron, tetrahedron, and the likes. The number of solid elements and required nodes are generated for each spot weld based on the indicator flag. A table is formed to group the generated solid elements in a cluster together, so that the force and moment resultants of the spot weld can be computed and assembled in a file.

Abstract: An impact reduction vehicle bumper system for a vehicle has a pedestrian safety plate, which is connected to a steel bumper beam and occupies the region between a pair of frame rails that are disposed on the front of the vehicle. The bumper beam is connected to side brackets, which are bolted to the vehicle frame rails. Frame rail extensions are located in front of the frame rails and are welded to the side brackets.

Abstract: An impact reduction vehicle bumper system for a vehicle has a pedestrian safety plate, which is connected to a steel bumper beam and occupies the region between a pair of frame rails that are disposed on the front of the vehicle. The bumper beam is connected to side brackets, which are bolted to the vehicle frame rails. Frame rail extensions are located in front of the frame rails and are welded to the side brackets.