Abstract: A multi-objective, multi-disciplinary design optimization (MDO) of an electric vehicle door was achieved with approximate model considering the door construction stiffness characteristics, the door vibration performance, and the door pole side crash safety comprehensively. Based on a single-row two-seater electric vehicle (EV) designed newly, an effective finite element models of the vehicle and the vehicle door were established and benchmarked experiments. According to the Euro Pole Side Crash Rules, the dimensions of 9 key parts were determined as design variables using a Hammersley experiment of design (DOE) method and a main effect analysis method. Based on the radial basis function (RBF) approximate method, a global respond optimization was achieved. The results show that by using an MDO method ensures the vibration performance with a good level, reduces the door mass of 7.5% with improving validly the stiffness of door and the pole side crash safety performances.

Key words: electric vehicle (EV), door, pole side crash, multidisciplinary design optimization(MDO); approximate model