Design and Crashworthiness of 4-Wheel Vehicle by Bio-mimicry of

Cuda Fish
Saswat Pradhan1, Vamsi. K.R.V.2, Naresh G3

Department of Automobile Engineering, SRM Institute of science and technology, SRM

Nagar, Kattankulathur, 603203, Kanchipuram, Chennai, TN, India.

E-mails: ss2296@srmist.edu.in

Abstract: The building up of idea is a basic requirement for any designing. Bio-
mimicry is the concept of latest class for solution of design problems, where building
up the ideas are done in a simplified way. From design point of view a car should have
good aerodynamics character. So Cuda fish is chosen because of its certain dynamic
features like its large and sleek body shape, its maneuverability and ferocious nature.
So, these characteristics infers possibility of designing a car with the features which
improves energy efficiency by adding adequate material. For that stainless steel having
outstanding properties which is selected for this model. The works in this paper consists
of designing a car taking Cuda fish as inspiration by scaling it up. Solidworks, Ansys,
MATLAB softwares are used for developing the model, keeping safety of driver in mind
using certain parameters, and this is done by solid sketching and then performing frontal
crash analysis for finding the impact results which is solved with regression equation
from Mini-tab tool and optimizing it with genetic algorithm. This is done by solving
parameters until the best output results reflected from series of analyses. Because this
method gives good results for designing final output model with developed parameters.
Where any other alternatives are costly process which are not that simplified version to
get better results.
Key words - Bio-mimicry, crash analysis, optimization, regression equation, Taguchi
method, genetic algorithm.

1. Introduction
In automobile sector the looks and appearance of vehicle is the most important factor for
customer impression. Analysis is done for knowing how the customers are seeking the cars and
what actually they need. This varies as sports, sedan, SUV, coupe, muscle etc.., so these brings
the challenges for the engineers to compete the tastes of customers and to design and attract
accordingly. This was also done when there was no development in technology. So, there will
be dilemma for designers to meet expectations. But now as of 21st century the expectations will
be very high due to advancement in technology, available sources and so on. On the other hand,
meeting of environmental aspects, eco-friendly and economic aspects need to be concerned.
For strict market and fuel prices the development of efficient reduction in drag is solution for
these problems. As this low drag not only reduce consumption of fuel but also contributes for
lowering the CO2 emissions. This drag can be reduced by optimizing the body shape which is
best alternative for all problems like alternating underbody, wheels, wheel arches, platooning
which may cause deterioration of vehicle’s cooling performance in real life. For drag problems
surface optimization is followed.
A Cuda or commonly known as Barracuda fish is a fish species that is famous for its fearsome
looks with abnormal hydrodynamics. They are sleek, nimble swimmers, and has good
maneuverability around obstacles. These fish species looks long in size and can contribute low
drag. These are snake typed body with sharp edges. So when this transformed to computer aided
model might show better stability and results even at higher speeds. Bio-mimic is the concept
of dealing the problems by observing nature and applying it into human life. This is the new
insight in this area. But there is no exact procedure for defining the process of bio-mimicry. But
this paper shows how a model is designed with this concept using software like Solidworks and
Ansys having each of separate importance and genetic algorithm is followed for its
optimization.

Fig 1: Cuda fish

Also, the vehicles performance and safety are the key features and the crashworthiness should
be good enough to save the life of the drivers. Crashworthiness refers to plastic deformation of
structures in vehicles. The moto for this is to safeguard people during impacts or Collison. For
this, the frontal area should be well executed in every aspect like structural, design and
materials. So, the dimensional examine and material is vital for protection and improved crash
worthiness. This is the important parameter which will be discussed in this paper. And for same
reason the driver’s aspects are to be considered, for that a variable set of parameters are used to
check the impact. For that Genetic programming is used to obtain the best set of parameters to
satisfy all the conditions for the safety and design standards even at driver’s position.
The material selection plays a major role in this area, for that several researches were also done
where a selection of suitable material in a vast field of resources is very important keeping
every property in concern. So here Austenitic stainless steel was chosen because of its adverse
characteristics like work hardening, formability and corrosion resistance, along with high
tensile strength which confers for outstanding crash-worthiness. Because of lower thickness of
this material itself enough for its good strength and it is light in weight which strongly bonded
to substrate and protects from mechanical impair
Thus, the paper consists of a simplified way of vehicle design of cuda fish model and how the
bio-mimicry concept is developed using software along with crash test is being performed. In
order to do so the necessary parameters are being considered with respective levels along with
regression equation is used to get objective function. Taguchi method is used to get the set of
parameters for ease in design. Genetic algorithm is considered for optimizing the implemented
process and results will be justified with CFD analysis. As this approach reduce the cost, saving
time and money.

2. Methodology

Identification of Problem

Defining objectives

Designing of the base model

Performing crash test and CFD test

Data collection & regression equation establishment

Optimization using Genetic algorithm

Results and findings

Fig 2: methodology

Initial step for this method is to find the problem with the existing models before designing a
bio mimic model. Although various works were done by researchers, the best method is used
in this. Then, moving to the approach the objectives are defined and then base model is made
by using Solidworks. In Ansys the crash test and cfd is performed for all the dimensional data
which obtained. Then regression equation is made from the considered parameters. And then
optimum results are obtained by optimizing with the multi-objective genetic algorithm tool in
Matlab. Then the final dimensions of the car body are found and final design is made and
confirmatory test and comparison of results are done in final stage.
2.1 Identification of Problem
In the initial stage, the thought of making design improvements in boxfish model was carried
out. But later it was found that it was a complete failure and the manufacturers have completely
misunderstood the boxfish. So later decision is done to go for Cuda fish.
The problem with the integration of bio-mimicry with vehicle aerodynamics is the compatibility
of features in the model, and how to implement and replicate that features. The method of
reduction in hydrodynamic drag involves the appropriate area at the front. And this can be also
countered with flow of fluid. This is also very commonly found in fish, as they generally tend
to be lengthy and narrow which reduces the strain drag additionally. Where pores and skin
friction may additionally the reason of drag reduction, however not for every spices. One of the
examples which has a majority of these is Cuda- fish. However, it has a simple geometry, it is
sleek in nature and its lengthy character is desirable for vehicles. Therefore, Cuda fish has been
selected and studied for aerodynamics behavior especially drag, stresses can be obtained from
analysis results.

2.2 Objective Defining

The design so inspired is developed by scaling up and the required changes are being
considered. The two independent variables length and height are countered as a basic change
in design of the bonnet shape. As these indirectly responsible for all aerodynamic aspects.
That’s the design to be made is responsible to satisfy the dependent variable that are considered.
So, the stresses so formed during analysis should be as low as possible with considerable drag
and maximum factor of safety. The alterations in independent variable cause change in mass.
So all these parameters were considered as objective of our goal.

2.3 Designing model

2.3.1 Sketching
Solidworks software is used to make 3D designs for this project. But designing the Cuda fish
modeled car was a bit challenging. So the reference was taken from 1967 Plymouth barracuda
car. All the dimensions like height, wheelbase, track width and engineering drawings are
obtained from internet. Engineering drawings are used to make the design, keeping the front,
side and top view of the engineering drawings of the car as per car dimensions and 3d splines
were made one by one carefully, and with this method whole car body was designed.
 Fig 3: this is how the car is designed using the engineering drawings

Fig 4: complete sketch of the half of car body

Fig 5: compete design of car body

2.3.2 Material selection

S301 grade of austenitic stainless steel was chosen as the car body material for this model. It
has good qualities like corrosion resistance, good welding capabilities, and also has good heat
treatment properties, austenitic stainless steel i.e. Fe - Cr - Ni containing alloys have the
advantage over aluminum alloys and carbon steels due to being highly strain rate sensitive. This
suggests that the faster the loading is applied the more the fabric will resist deformation.
Additionally austenitic stainless steel has the potential to collapse progressively during a
Collison in a controlled and predetermined manner which is desirable in applications of
automotive applications.

Table 1: Physical properties austenitic stainless steel

LENGTH HEIGHT
Density (kg/m3) 7880
Elastic Modulus (GPa) 193

Yield strength (Mpa) 276

Poisson’s ratio 02.65

Specific Heat 0-100°C 500
(J/kg. K)
2.4 Performing crash test and CFD test
For crashworthiness test Ansys explicit dynamics was used. In Ansys workbench nonlinear
materials are chosen like concrete and stainless steel and properties were changed as per the
steel grade. 3mm is assigned as thickness for sheet metal. So, after material selection in the
setup window, and the rigid all was fixed, all vertical motion of car was restricted and 120 kmph
of velocity was given to the car facing towards the rigid-wall. For solution selection of von-
misses stress, deformation is selected and then solved the problem.

Fig 6: Energy conservation while crash

This graph shows the energy conservation while crashing. In the graph it is clear that during
impact the internal energy of car is increasing but the kinetic energy is increasing at the same
time. So, it is concluded that this proposed model is correct and can rely on the results that got
from it.

Fig 7: equivalent stress (von-mises) contour of the base car body design

Then again CFD analysis was done in order to improve the drag coefficient. For that ansys
fluent was used. 2d cfd technique was best approach, as the main area of concern was the bonnet
angle and shape. So, 2d cfd was used rather than 3d cfd. In CFD Process for boundary
conditions choosing medium as air, made an enclosure and kept the wind speed at 20 m/s. From
that drag force data was collected out of it. The Cd was 0.2973.

Fig 8: flow distribution of air with the base car-body design

2.5 Data collection & Regression equation establishment

To predict the exact dimensions of car-body, certain equations and relations are needed, based
on that optimum results can be obtained. So, Minitab tool was used to create and establish
relations between the considered parameters. Then by Taguchi method in design of
experiments, it gave us certain points instead of all the points, which helped in saving time. In
Taguchi method 5 levels of design was assigned for both length and height of bonnet. Then it
suggested 30 combinations. Using all these combinations again 30 design are made using the
base car body as reference and crash test and cfd test was performed on all the models. Then
The von-mises equivalent stress, FOS, drag coefficient, mass of all models are collected as
these are the parameters on the basis of which the proposed model car has to be optimized. The
stress values are taken from the driver side of the car-body as to reduce the stress, keeping
driver safety as main concern.
Table 2: Taguchi Design Table
LENGTH HEIGHT VON-MISES FOS at that Co-Efficient of drag MASS
STRESS point (Cd)
0 0 60.174 4.580 0.297370 406.72
-170 -40 62.735 4.390 0.279343 392.95
-170 -20 61.378 4.490 0.297244 393.78
-170 10 54.569 5.050 0.315625 395.77
-170 30 49.733 5.540 0.320582 396.71
-170 50 47.226 5.840 0.327212 397.95
-170 0 65.079 4.240 0.305382 394.94
-70 -40 65.108 4.230 0.267265 399.46
-70 -20 63.904 4.310 0.281813 400.59
-70 10 60.223 4.580 0.287583 401.10
-70 30 54.233 5.080 0.320334 403.24
-70 50 49.954 5.525 0.362224 404.43
-70 0 62.902 4.380 0.280578 401.75
30 -40 57.266 4.810 0.275041 406.46
30 -20 51.745 5.330 0.277848 407.57
30 10 49.084 5.620 0.311526 409.50
30 30 47.117 5.850 0.309738 410.52
30 50 39.792 6.930 0.314404 411.66
30 0 56.392 4.890 0.308805 408.79
120 -40 48.854 5.640 0.291774 412.64
120 -20 49.282 5.600 0.296789 413.86
120 10 46.635 5.910 0.308535 415.66
120 30 41.375 6.670 0.314241 416.73
120 50 39.923 7.020 0.303797 417.90
120 0 50.138 5.504 0.297216 415.07
200 -40 43.231 6.380 0.297536 418.05
200 -20 40.889 6.740 0.310653 419.52
200 10 40.624 6.790 0.321190 421.15
200 30 38.486 7.170 0.323155 422.67
200 50 34.668 7.960 0.354867 423.81
200 0 44.067 6.260 0.315430 420.95

In this way the

After all the analyses done the value of all the parameters for
Taguchi method gives
respective dimensions are collected and written
various dimensions to
design
Regression Equation
Regression equation was formed between all the parameters (von-mises stress, FOS, drag
coefficient, mass) with length and height of bonnet which are considered as independent
variable of all equations.

VON-MISES Stress = 57.288 - 0.0777 LENGTH - 0.1810 HEIGHT - 0.000185 LENGTH *

LENGTH - 0.002231 HEIGHT * HEIGHT + 0.000254 LENGTH * HEIGHT + 0.000001 LENGTH*
LENGTH * LENGTH + 0.000018 HEIGHT * HEIGHT * HEIGHT + 0.000001 LENGTH * LENGTH*
HEIGHT + 0.000001 LENGTH * HEIGHT * HEIGHT

Fig 9: Regression Analysis: Co-Efficient of drag (Cd) versus LENGTH, HEIGHT

FOS at that point = 4.8642 + 0.005104 LENGTH + 0.01472 HEIGHT + 0.000018 LENGTH *
LENGTH + 0.000263 HEIGHT * HEIGHT - 0.000002 LENGTH * HEIGHT
 Fig 10: Regression Analysis: fos at that point versus LENGTH, HEIGHT

Co-Efficient of drag (Cd) = 0.29391 + 0.000018 LENGTH + 0.000553 HEIGHT + 0.000001 LENGTH
* LENGTH + 0.000001 HEIGHT * HEIGHT - 0.000001 LENGTH * HEIGHT

Fig 11: Regression Analysis: Co-Efficient of drag (Cd) versus LENGTH, HEIGHT
Mass = 406.530 + 0.069405 LENGTH + 0.05731 HEIGHT + 0.000008 LENGTH * LENGTH +
0.000020 HEIGHT * HEIGHT + 0.000019 LENGTH * HEIGHT

Fig 12: Regression Analysis: MASS versus LENGTH, HEIGHT

These are the required 4 regression equation and the R squared value of all the equation are
93.65%,93.74%,74.7% & 99.2% respectively. This concludes that these equations are reliable
to predict optimum values.

2.6 Optimization using genetic algorithm

By Matlab optimization tool, prediction was made for getting the optimum length and height
values. For that multipurpose genetic algorithm tool was used to optimize, as our motto was to
minimize all the objective function. But fos was to be maximized. So modifing the fos
regression equation to be as 1/fos. So the following is the objective functions of the fos
optimization
fos = 1/(4.8642 + 0.005104 *x(1) + 0.01472* x(2) + 0.000018 *x(1)*x(1)+ 0.000263
*x(2)*x(2) - 0.000002* x(1)*x(2))
Where x (1) = length and x (2) = height and the rest all 3 equations remains same
Then by putting independent variables as 2 and by setting the upper and lower limits it gave the
optimum points that are needed. Then the final design of model is made using these dimensions
and comparison was done with all the result with the base car body design. The optimized value
for length and height was found to be 179.32mm increase and 46.62 mm increase respectively.
 Fig 13: this shows the optimization tool setup in matlab

2.7 Final result and comparison

Table 3: comparison of initial and final values
parameters Base model Optimized model
theoretical practical
Von-mises stress 60.174 35.721 38.174
(Mpa)
Factor of safety 4.580 7.57 7.22
Coefficient of drag 0.2973 0.317 0.31318
(Cd)
Mass (Kg) 406.72 422.107 421.57

Fig 14: von-mises stress contour of final car body design

 Fig 15: flow distribution of air with final car body design

Fig 16: initial design

Fig 17: final design

Results and Conclusions

Thus, the results obtained from the following can be concluded. In this work the Von-misses
stresses, Total deformation, Factor of safety and mass are considered as a final response. The
design was made considering 5 levels deploying Taguchi method. Taguchi technique was used
and its consequences to estimate the relation among the parameters. Genetic set of rules was
taken into consideration for optimizing the applied procedure and consequences can be justified
with CFD analysis specific dynamics. The regression equation has generated used as an
objective function to optimize using Genetic algorithm from optimization toolbox in
MATLAB. And optimized results are validated through confirmatory test and the results are
found satisfying. As this method will lessen the cost, saving time and money.
The parametric optimized values:
1. Von-mises stress - 38.174 Mpa – decreased by 36.56%
2. Factor of safety - 7.22 – increased by 57.64%
3. Coefficient of drag - 0.31318 – increased by 5.314%
4. Mass - 421.57 Kg – increased by 3.6%

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