Finite Elements in Analysis and Design 91 (2014) 115126

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Finite Elements in Analysis and Design

journal homepage: www.elsevier.com/locate/finel

Numerical analysis and optimal design for new automotive

door sealing with variable cross-section
Zhu Wenfengn, Wang Jie, Lin Peijian
College of Mechanical Engineering, Tongji University, Shanghai 201804, China

ar t ic l e i nf o

a b s t r a c t

Article history:
Received 18 July 2013
Received in revised form
27 May 2014
Accepted 30 June 2014
Available online 17 August 2014

Automotive door sealing system isolates passenger compartment from water, dust and wind noise. It has
the most direct inuences on door-closing performance, which is determined by cross-section design in
terms of its appropriate Compression Load Deection (CLD) property. Traditional sealing structure has
uniform geometrical cross-section. It has the shortcomings of bad tting in corner parts with large
curvatures, causing inaccurate door-closing effort design. Regarding the door panel's complex 3D prole,
numerical analysis and optimal design for new sealing with variable cross-section are developed in this
paper. Firstly, the whole sealing is partitioned into several parts. For four nearly straight segments,
conventional 2D numerical analysis can still be used to obtain desired geometrical conguration. For
other four curved corner parts with large curvatures, 3D numerical analysis of door closing is applied.
Secondly, 2D geometrical cross-section optimization is proposed. Instead of three variables in previous
research, ve variables are selected for featuring cross-section geometry and used for next CAD
reconstruction with more precision. After comparison between Back Propagation (BP) neural network
and the Kriging surrogate model, BP neural network which performs better and efcient in this
automotive design optimization eld is applied for extracting nonlinear mapping between ve crosssection parameters and compression load, which were parallely optimized by Genetic Algorithm (GA)
and its efciency and accuracy are compared with another evolutionary algorithm of Particle Swarm
Optimization (PSO). Thirdly, 3D numerical modeling of four curved corner parts' closing process is
realized, of which twisting and bending effects during seal assembly are taken into account, thus
minimizing theoretical error and producing more realistic solution. Consequently, the desired geometrical congurations for both straight parts and corner parts satisfying designated CLD property can be
obtained and the whole sealing can be achieved with variable cross-section, resulting in an ideal door
closing effort. Finally, a Matlab-based platform has been developed to assist the design and optimization
process. Experiment and case study indicates that it provides an effective method for new door sealing
design with variable cross-section.
& 2014 Elsevier B.V. All rights reserved.

Keywords:
Variable cross-section
Geometrical optimization
Door seal closing effort
Finite element analysis

1. Introduction
Automotive door seals are installed in narrow gaps between
door and body frame along the perimeters of the opening panels,
as shown in Fig. 1. They prevent water and dust from entering
passenger compartment and accommodate metal manufacturing
variations [1]. Door-closing effort is determined by six factors of
seal rubber's compression load, cabin volume, door weight, latch,
etc. It was revealed that door sealing consumes 3550% energy
during the door closing process [2], thus making it become the
dominant role for door closing effort design [35].

Corresponding author.
E-mail address: Zhuwenfeng@tongji.edu.cn (W. Zhu).

http://dx.doi.org/10.1016/j.nel.2014.06.012
0168-874X/& 2014 Elsevier B.V. All rights reserved.

As a component intimately associated with human sensibility,

automotive door sealing design includes suitable cross-section's
geometrical parameters, as well as appropriate rubber material
property, which result in the desired Compression Load Deection
(CLD) and the nal door-closing efforts. Better sealing performance requires both higher reaction force and a wider contact
area. However, better door-closing performance requires the
opposite conditions [6]. A good door sealing design needs to
satisfy both the sealing quality and the door-closing performance.
Consequently, door seal design is dened as the compromise
between these two reciprocal design targets, which have several
features of nonlinearity, such as hyper-elastic rubber material,
rubber's large deformation and rubbermetal contact behavior.
Conventionally, door-closing effort design and measurement
have mostly relied on experimental methods. Ordieres-Mer

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W. Zhu et al. / Finite Elements in Analysis and Design 91 (2014) 115126

Fig. 1. Illustration of door sealing.

tested quasi-static driven door forces [7]. Egashira et al. measured

door-seal reaction force and calculated the changes in the inner
cabin's atmospheric pressure by air ow [8]. However, the narrow
and limited closed space between door seal and door panel makes
it difcult to monitor the deformation process and hard to obtain
the necessary data of compression load by the traditional measurement methods. Experimental methods have disadvantages in
determining the many factors related to door closing effort design
and are not particularly feasible for new development of optimized seal design regarding to cost and time.
Nowadays, computational efforts have been implemented for
door seal design. For instance, 2D cross-section of the door seal is
modeled and analyzed, making extraction of the reaction force and
contact area conveniently [9]. Kim et al. developed a numerical
process to predict minimum door-closing velocity and virtual
reaction force versus closing time data [10]. 3D door-closing
analysis, using explicit code, was introduced to produce a more
realistic solution. Nonlinear nite element analysis is applied to
investigate seal performance, permitting numerous design iterations to be evaluated quickly prior to manufacturing and testing
the rst prototype parts.
Although numerical analysis makes great contributions to the
door seal design, there still exists some problems for this high
non-linear behavior. Door seal is generally in the form of dual
extrusion bulbs of metalloid sponge and dense rubber. Its mechanical properties vary with the amount of deformation, previous load
history, temperature, frequency and amplitude of the motion [1113].
In order to predict the accurate door closing performance, seal
material properties must be investigated carefully, which is a challenging task in computational mechanics due to large deformations and
the nearly incompressible nature of rubber [1417].
Moreover, traditional sealing system has uniform geometrical
cross-section. Very few parameters of height and wall thickness
are selected for geometrical description. It is simple for design, but
would cause inaccurate reconstruction of geometrical conguration. Because the cross-section remains unchangeable, it is easy for
manufacturing, but has the shortcoming of bad tting in large
curvature corners and cannot satisfy the varied CLD requirements
from different locations of door like the roof part, A-pillar part,
B-pillar part and sill part.
Recently, variable cross-section extrusion technologies have
been invented. With the computer control of extrusion die, rubber
can be manufactured with changed cross-section. With regard to
automotive door's complex 3D prole, new sealing with variable
cross-section is desired and can be achieved with the help of new
extrusion technology. Consequently, more cross-section geometrical parameters are required. Optimal design of new sealing
system could benet greatly from numerical analysis in term of
efciency and research cost. Regarding to material nonlinear,
contact nonlinear and geometrical nonlinear of door sealing, this

paper provides a practical numerical approach for new automotive

door sealing with variable cross-section.
It rstly presented the door sealing partition process based on
closing efforts design. A typical door sealing is geometrically
divided into eight segments, considering the curvature change of
true prole. Secondly, combination of experiment and numerical
analysis is used to identify the hyper-elastic material model of
door seal rubber. Thirdly, it solved the problem of cross-section's
geometrical conguration and optimal variable selection. By using
BP neural network, the nonlinear mapping mechanism between
ve cross-section parameters and the desired CLD is established.
Based on Genetic Algorithm, cross-section parameters are parallely optimized. Fourthly, numerical modeling of 3D door closing is
constructed for corner parts, taking into account the inuence of
twisting and bending during door seal assembly. By using 2D
cross-section optimization for nearly straight segments of door
seal and 3D numerical analysis for the rest of the corner parts, the
whole sealing can be designed with variable cross section. Finally,
a Matlab-based re-exploration platform has been developed,
assisting this new sealing system design and demonstration.

2. Door sealing partition based on closing efforts design

Door sealing accounts for a substantial portion of door closing
effort. Geometrical and topological parameters of seal cross-section, as well as the appropriate rubber material property, would
result in a desired Compression Load Deection (CLD) and doorclosing performance in the end. Traditional sealing structure has
uniform geometrical cross-section. However, because of door
metal panel manufacturing deviation on which seal rubber was
mounted and the 3D true corners parts with large curvature, this
type of structure has the shortcoming of bad tting, causing
inaccurate door-closing effort design. New door sealing needs
variable cross-section so that it can bring about change in the
CLD curve at different locations, thus satisfying the desired
different compression loads and seal qualities.
Considering the non-planar prole of practical sealing in
engineering, a typical door sealing is partitioned into eight segments, of which four are nearly straight segments and four are
corner parts with large curvatures, as shown in Fig. 2. The whole
sealing compression load required by good door seal performance
is then distributed into each part. Since different compression
loads could be raised from different cross-sectional designs of
sealing structure, each of the eight segments' cross-section parameters needs to be optimally designed based on the distributed
compression load, so that sum of them could fulll the desired
total door closing effort.
For four nearly straightly segments, conventional 2D numerical
analysis of compression process can still be used because of the
unchanged compression direction of the door sheet metal.

Fig. 2. Partition of door sealing system.

W. Zhu et al. / Finite Elements in Analysis and Design 91 (2014) 115126

117

Fig. 4. Dumbbell-like test specimen.

Fig. 3. Distribution of door-closing efforts.

However, the 2D cross-section's geometrical conguration of

different segments need to be re-designed in order to obtain the
assigned different compression loads. For four corner parts with
large curvatures, 3D numerical analysis of door closing is applied,
considering the bending and twisting effect caused by large
curvatures and the pre-load effect of door sealing assembly
process. The whole partition is shown in Fig. 3.

Fig. 5. Stretching equipment.

3. Verication of sealing rubber material

Door seals use Ethylene Propylene Diene Monomer (EPDM)
sponge rubber. It exhibits nonlinear force versus displacement
response characterized by hyper-elastic models. Different strain
energy functions are used to describe the behavior of rubber
material, such as the MooneyRivlin, Ogden, etc. Experimental and
numerical analysis are applied for selection of the appropriate
hyper-elastic material model.
Firstly, uniaxial tension experiments take place, and the data
achieved is tted to the mechanical coefcients of the various
material models which are applied to the nite element analysis.
Then the nite element results are compared with the experimental ones to obtain the most suitable material model.
3.1. Test of rubber uniaxial extension
Test process is performed based on the standard GB/T 528-2009.
The dimensions of test specimen are shown in Fig. 4, which also
illustrates the plane strain nite element analysis of test specimen.
It is obvious that the middle part of the test specimen with uniform
distributed stress is the effective coverage for testing data collection.
Three test specimens are stretched at the speed of
500 750 mm/min until fracture. The cracked position must be
within the effective coverage. The testing process is shown in Fig. 5
and results are shown in Fig. 6.

Fig. 6. Results of tension test.

Table 1
Coefcient of hyper-elastic constitutive equations.
Mooney (2)

Ogden

Foam

ArrudaBoyce

Gent

c10 0.02173

 0.08792

0.04746

0.1531

c01 0.21513

 3.75166

0.08837
1.87486
3.81536

5.937e 10

Jm  497636

3.2. Coefcients of the various material models

Table 1 displays the coefcient tting results of hyper-elastic
constitutive equations in MSC.Marc, which can be applied in the
numerical analysis for the material model verication.

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W. Zhu et al. / Finite Elements in Analysis and Design 91 (2014) 115126

3.3. Hyper-elastic material model verication

4. 2D cross-section optimization for straight segments

In order to predict sealing performance and door-closing force,

the chemical, mechanical properties and the constitutive model of
rubber material must be considered; moreover, the different
orders of the same material constitutive model also inuence
the reliability of the simulation results.
In this study, we utilize the method in Ref. [1] to select suitable
material model for the experimental results. Finally, the Foam
model is selected in the simulation, as shown in Fig. 7, and its
strain energy function is shown in the following equation:

In terms of appropriate CLD property according to the distributed sealing compression load, geometrical parameters of four
straight segments' cross section need to be designed and optimized. In order to establish the implicit relationship between the
section parameters and the CLD property, BP neural network is
adopted to extract the highly nonlinear mapping mechanism with
the help of Design Of Experiments (DOE) to provide sufcient
training samples. Then, genetic algorithm is applied to parallely
search cross section parameters.

N
n n n n
1 2 3  3 n 1  J n
n 1 n
n 1 n
N

Among them, n , n and n are the material constants. i are

the principal stretch ratios.

4.1. Variables for featuring 2D cross-section

Conventional method uses three simple variables of cross
section height, rubber thickness and annulus diameter to describe

Fig. 7. Simulation results with various material models.

Fig. 8. Conventional selection of cross section variables.

Fig. 9. Effect of rib structure on the seal CLD performance.

W. Zhu et al. / Finite Elements in Analysis and Design 91 (2014) 115126

seal cross-section. It ignores rubber's non-uniform and irregular

shape. Furthermore, it has not taken into account the inuence
of special convex structure called rib, as shown in Fig. 8. In fact,
rib segment is very sensitive to compression load according to
study in this paper, and a penalty function technique is used to
handle the contact constraints in the nite element contact
simulation.
Fig. 9 shows the poor sealing performance caused by rib and
the comparison of compression response with and without rib
structure. It can clearly be seen that rib segment would cause an
excessive door-closing force, meaning that the traditional simple
three variables cannot describe cross-section geometry without
considering the rib structure. Considering the non-uniform shape
and protruding structure, 2D seal section geometry must be
reasonably divided into ve parts, as shown in Fig. 10.
After cross-section partition, appropriate variables need to be
selected for featuring cross-section geometry. Five variables of
angle , angle , distance d, associated with other two thickness
variables, are proposed in this paper, as shown in Fig. 10. It covers
the possible changes in term of the thickness, shape and height
of the sponge tube. The ve variables can not only ensure the

119

portions I, II and III of the sponge tube to be reconstructed with

minimum deviation, but also make the cross-section's geometrical
design more convenient and accurate.

Table 2
Variable ranges and level denition.
Part Variable number Variable type Range
I

II
III
IV

1
1
0

Angle
Angle
Distance d
Thickness t1
Thickness t2

Level

0101
0
2.5
5
7.5 10
2617 91
17
21.5 26
30.5 35
15 74 mm 11
13
15
17
19
0.8 mm
0.8
1.1
1.4
1.7
2
0.82 mm
0.8
1.1
1.4
1.7
2

Fig. 12. Comparison of seal cross-section compression experiment and numerical

analysis.

Fig. 10. Seal cross section partition and variable selection.

Fig. 13. Fixture of seal compression experiment.

Fig. 11. Industrial quality evaluation of the seal CLD.

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W. Zhu et al. / Finite Elements in Analysis and Design 91 (2014) 115126

4.2. Objective function for cross-section optimization

The result of seal cross section design is its CLD property which
can meet the engineering practical requirement, as shown in
Fig. 11. The measured CLD for certain 2D cross-section must be
located in the upper and low limit zones as shown in the shadow.
To evaluate the performance of a seal product under actual
conditions, the seal deformation is checked in three critical
congurations depending on the relative position of the door
and frames, denoted by D  2, D, D 2 in Fig. 11. D represents the
complete closing condition, while D 2 and D 2 are slightly less
and more deformed conditions, respectively.
According to the industrial application, the objective function
for cross-section optimization can be obtained and, shown in the
following equation:
3

f ; ; d; t 1 ; t 2 i F i  f i 2

i1

Among them, F i is the compression load of the three key

compression displacements; f i is the center values of the deviation
range of the seal design requirement; i is the weight, in this paper
whose f1 2.5 N, f2 3.5 N, and f3 4.5 N. According to the seal
energy consumption calculation formula, the relationship of
weight between F1, F2, and F3 is F1 oF2 oF3, therefore, 1 0.28,
2 0.33, and 3 0.39.

4.3. BP-based mapping mechanism extraction

Because of the irregular shape and hyper-elastic rubber material of door sealing, there exists strong nonlinear mapping
mechanism between its input geometrical variables and output
compression load, which are difcult to be expressed by the
traditional explicit way. BP neural network can realize complicated
implicit mapping as long as it has enough hidden layers and
points. It was adopted in this paper for extracting mapping
between ve variables of cross-section and the desired CLD
response with the closest approximation algorithm.

4.3.1. DOE-based training samples establishment

BP neural network needs sufcient training and learning
samples. With the Design Of Experiments methods, the input of
cross-section parameters is grouped as ve variables and ve
levels, as shown in Table 2; orthogonal table is used to arrange the
experiment samples and 25 groups of samples are numerically
analyzed to obtain the output values of F1, F2, and F3.

4.3.2. Numerical analysis of compression load

Seal compression in a narrow gap between door metal panel
during door-closing is characterized as large deformation of hyperelastic material, showing strong geometrical and material nonlinearity. Finite element analysis aiming at obtaining the training
data collection for neural network must do more work in the
aspects of element types, material model and boundary conditions. The results are shown in Fig. 12.

4.3.3. Experiment of cross-section compression

To verify the numerical analysis of cross-section compression,
experiment of real door seal compression is performed, as shown
in Fig. 13. Since the CLD property is dened by normal compression to cross-section, special xture with upper part and lower
part is designed and made. The upper xture simulated the door
sheet metal, while lower xture as body frame metal. By adjusting
the position of upper xture and lower xture, it can ensure that
not only the compression load's direction is vertical to crosssection, but also the real spatial assembly position in relation to
door seal, door panel and frame panel. The results are listed in
Table 3. The least error for compression load at D 2 between
experimental and numerical analysis is 2.32%, which shows a quite
good agreement, indicating that numerical results can be used for
BP mapping modeling.

4.3.4. Results of mapping mechanism

A three layers BP neural network is established to model the
implicit mapping mechanism using large quantity of training
samples learning. The neuron numbers of the input and output
layer are 5 and 3 respectively. After taking the training function as
trainlm, the transfer functions as tansig and purelin, the
highest training number is 7000 and the training goal is 1e  7;
then each neural network with different hidden layer neurons is
made to learn the training samples, whose results are shown in
Table 4 (due to the random training process of the neural network,
the data in the table is derived from the comparison of 10 training
results).
The number of the neurons of the hidden layer is chosen as 18,
and other parameters are listed as the above content. Fig. 14 shows
the convergence curve of the training mean square error of the
neural network, and the comparison of the network output and
the sample target is also shown in Fig. 15.

Table 3
Comparison of test and simulation results.
Original seal

D  2(2.5 mm)

D(4.5 mm)

D 2(6.5 mm)

FEA (N)
Experiment (N)
Design index (N)
e (%)

5.035
5.926
2.5 71
 15.03

7.083
8.033
4.5 7 1
 11.83

8.426
8.626
6.5 7 1
 2.32

Fig. 14. Convergence curve of BP network training error.

Table 4
The effect of the hidden layer neurons on neural network.
Hidden nodes

12

13

14

15

16

17

18

19

Mean square error

Training number
Convergence to local optimal solution

0.1034
7000
60%

0.0179
7000
60%

9.93e  8
6132
50%

0.0128
7000
60%

9.35e 8
4139
20%

6.87e  8
1134
10%

9.46e  8
1307
10%

9.71e  8
5960
10%

W. Zhu et al. / Finite Elements in Analysis and Design 91 (2014) 115126

121

Fig. 15. Sample targets and network outputs.

Table 5
Values of theta0, lob and upb.
theta0

lob

upb

[0.08, 0.1, 0.1, 0.02, 0.02]

[0.01, 0.01, 0.01, 0.01, 0.01]

[1, 1, 1, 1, 1]

Table 6
Comparison of the neural network results and kriging ones.

Fig. 16. Curve of the tness.

Load

Simulated value (N)

Neural network result (N)

Kriging result (N)

F1
F2
F3

5.0353
7.0833
8.4259

4.2255
5.9272
7.2972

4.2256
6.3204
8.5258

Table 9
Best tness and optimal result.

Table 7
Average tness of GA and PSO.

Variable

(deg) (deg) d (mm) t1 (mm) t2 (mm) Best tness value

Optimal result
Original
section

4.39
4.00

17.47
26.00

16.94
13.86

1.11
1.26

1.36
1.52

0.0054
12.0471

Table 10
Comparison of the optimal results and the simulated ones.

Optimal method

GA

PSO

Average tness

0.053394349

0.053709607

Load Requirement
(N)
F1
F2
F3

Table 8
Operating parameters of genetic algorithm.
Population
size

Binary places of
variables

Crossover
probability Pc

Variation
probability Pm

Generation
gap G

40

20

0.62

0.017

4.3.5. Comparison between Kriging and BP neural network based

on original section
The software package Design and Analysis of Computer Experiments [18] (DACE) is applied to establish a Kriging model, which is a
Matlab toolbox for working with Kriging approximations to computer
models. There are two important functions in the toolbox, namely
dacet and predictor, as shown in the following equations:
dmodel; perf  dacefitS; Y; regr; corr; theta0; lob; upb

y predictorx; dmodel

The parameter theta0 in dacet is the key to build a ne

surrogate model, and there is a principle that when theta is small,
the model is relatively smooth while too simple, on the other
hand, if theta is too large; the model will change ercely in local

2.5 7 1
3.5 7 1
4.5 7 1

Optimal
value (N)

Simulated
value (N)

(Optimal-simulated)/
simulated (%)

2.120
2.916
4.144

2.187
3.167
4.042

 3.1
 7.9
2.5

scope and over t. After lots of trials, we choose the poly0

regression function and the gauss correlation function; with the
assumption of anisotropy we choose the following starting point
and bounds for theta0, as shown in Table 5.
Because of limited samples, in this paper BP neural network is
compared with Kriging method by predicting the original section.
Table 9 shows the ve variables of the original section and the
comparison of BP neural network results and Kriging ones is
shown in Table 6.
It can be seen that the Kriging results match the simulated
values a little better; however it is time consuming to choose a
proper value for theta0, lob and upb, which means less efcient
than BP neural network.

4.3.6. Comparison between GA and PSO optimization

on cross-section parameters
Genetic algorithm (GA for short), simulating the natural biological evolution process and nature genetic mechanism, is a

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W. Zhu et al. / Finite Elements in Analysis and Design 91 (2014) 115126

Fig. 17. Comparison of original section geometry and optimized one. (a) The section geometry of the optimization result and (b) optimal results of FEA.

Fig. 19. Finite element model of B-pillar seal assembly.

Fig. 18. Curvature analysis of the door corner parts.

classical optimization method. Particle swarm optimization (PSO

for short), rooting from simulation of swarm of bird, also solves
optimization problems [19].
In this paper, GA is compared with PSO through the same
surrogate model established by BP neural network. The optimization efciency is evaluated by the average tness concluded from
50 calculations, and the comparative results indicate that GA can
obtain a better average tness as shown in Table 7, which means
that GA performs a little better than PSO.

4.3.7. GA-based cross-section parameters optimization

Genetic algorithm is applied for optimization of ve selected
cross-section parameters. The variables classication and range

are shown in Table 2; the tness function is shown in Eq. (2). After
many trials, its best operating parameters can be obtained and are
listed in Table 8. Fig. 16 shows the curve of tness changing during
evolution. The comparison of an optimal result and the original
section size is shown in Table 9 and its corresponding compression
load values are seen in Table 10.
Using the GA-based optimal parameters, a new cross-section's
geometrical shape is reconstructed precisely and it was again
analyzed numerically to obtain corresponding new CLD curve.
New cross-section geometry and new CLD were compared to the
corresponding old ones and the results are shown in Fig. 17(a).
Fig. 17(b) shows the nite element analytical process and its result
is listed in Table 10.
It can be seen that the rib structure matches the prole of
upper panel perfectly. The contact and seal area are uniformly

W. Zhu et al. / Finite Elements in Analysis and Design 91 (2014) 115126

123

Fig. 20. Simulated results of the B-pillar seal.

5.1. Large curvature's inuence

Fig. 18 shows door corner parts, of which the curvature was
analyzed. It indicates that corner of B pillar has the biggest
curvature change. When corner parts were compressed during
door closing, the compression load would be generated from both
the normal force as well as the tangent force and twisting force,
causing inaccurate calculation of compression force if only using
the CLD property obtained from 2D cross-section analysis.
5.2. 3D compression model construction
Fig. 21. Dynamic compression load of B-pillar seal.

distributed along the perimeter of upper panel, which greatly

increases the seal performance. Three specic key measurement
points of CLD curve, such as D  2, D and D 2, before and after are
both listed. The errors of the ttest solution optimized by the
genetic algorithm are all within 8%, which reaches the requirement of the engineering application. It indicates that the precision
of the non-linear global mapping relationship between the section
parameters and the CLD curve, established by BP neural network,
is comparatively high.

5. 3D numerical analysis for corner parts

Door panel's prole is 3D non-planar curve, causing the related
door seal to have complex shape and layout. Previous research
regarded the whole seal as a single segment. When calculating the
total compression load, it just multiplies the CLD results of
compression load per unit length with the total length. This
simplication ignored the complicated interaction of twisting
and bending for corner parts with large curvatures. 3D numerical
analysis was modeled for calculating four corners' door sealing
compression load.

The B-pillar with the biggest curvature is adopted to examine

the compression efforts by 3D simulation of door-closing process.
In order to exhibit the distinct nonlinearity of rubber materials and
the complex deform behavior caused by contact, Hypermesh is
used for meshing and MSC.Marc is applied for nonlinear analysis.
Fig. 19 is the nite element model of B-pillar assembly on door
metal panel. It is established with the tetrahedron mesh controlled
by the size of 0.6 mm. The door sheet metal and body frame metal
are dened as rigid body and the seal is regarded as the deformable body characterized by the constitutive model of Foam after
verication of sealing rubber material as mentioned.
Simulation steps can be described as xing the pedestal part of
the seal, then rotating the body frame metal for 91 around the axis
until the door closing position is reached, as shown in Fig. 19. The
large curvature of corner prole and changing compression direction caused by rotation of door sheet metal are both taken into
account, so that large deformation and compression efforts can be
simulated accurately.
5.3. Compression load for corner parts
Fig. 20 illustrates the simulated results of the B-pillar seal with
length of 82.24 mm. From the results, it can be learned that the
direction of seal deformation is gradually changing from one end
plane to the other along the installed prole. Meanwhile, the
dynamic compression load versus the door closing angle is

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W. Zhu et al. / Finite Elements in Analysis and Design 91 (2014) 115126

Fig. 22. Design results of variable cross-section seal system.

Table 11
Parameters of variable cross-section seal system.
(deg)

(deg)

d (mm)

t1 (mm)

Corner-1-a
Corner-1-b
Straight-1

6
6
0

29
30
25

14.96
14.86
16.82

1.44
1.55
1.87

Corner-2-a
Corner-2-b
Straight-2

5
6
0

16
29
24

13.9
15.3
15.12

1.32
1.49
1.85

Corner-3-a
Corner-3-b
Straight-3

6
6
0

29
29
24

14.96
14.96
15.78

1.44
1.44
1.59

1.64
1.64
1.27

Corner-4-a
Corner-4-b
Straight-4

6
6
6

29
29
29

14.96
14.96
14.96

1.44
1.44
1.44

1.64
1.64
1.64

t2 (mm)
1.64
1.48
1.7
1.3
15.3
1.3

extracted, as shown in Fig. 21, from which we can learn that the
starting angle of contact between the seal and body frame metal
is 8.451.

Fig. 23. Door closing effort with angle of 91.

W. Zhu et al. / Finite Elements in Analysis and Design 91 (2014) 115126

125

Fig. 24. Door closing efforts under wide open.

6. Case study and Matlab-based platform

By using the many steps of compression load distribution, door
sealing portion, 2D cross-section optimization for straight parts
and 3D numerical analysis for corner parts, the new automotive
door sealing with variable cross-section could nally be achieved.
Fig. 22 and Table 11 show the nal design results.
Combined with other 5 factors, like door weights, cabin air
pressure, as mentioned above, an advanced integrated Matlabbased platform is developed to perform the nal design and
optimization of total door closing effort design. Figs. 23 and 24
show its application for an engineering case study.

7. Conclusion
[1] Five variables are selected for featuring seal cross-section's irregular geometry, whose nonlinear implicit mapping with required
CLD curve can be extracted by BP neural network and nally be
optimized by the combination with Genetic Algorithm.
[2] Door panel's large curvature causes sealing, bending and
twisting effect on door closing effort. 3D numerical analysis
of door corner part assembly and closing process must be
modeled so that corner's compression load is calculated
directly instead of using CLD from 2D analysis.
[3] By door sealing compression load distribution, portion into
straight and curved segments, 2D cross-section optimization
for straight parts and 3D numerical analysis for corner parts,
new sealing with variable cross-section based on complex true
prole is developed.

Acknowledgment
This research is supported by the NSFC-China (National Natural
Science Foundation of China) Project (No. 51275359), Project of
Shanghai Key Laboratory of Digital Manufacture for Thin-walled
Structures project (No. 2012005) and Project of Tongji-Qingpu

Co-Research Platform (201109, 201305). Director Dr. DAI Yuankan

and Research Manager XIA Guoyong of HUAYU-COOPER Standard
Sealing System CO., LTD. have made lots of contribution for this
research project.
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