汽车工程 ›› 2024, Vol. 46 ›› Issue (7): 1314-1322.doi: 10.19562/j.chinasae.qcgc.2024.07.018

• • 上一篇    

一体化压铸铝合金前机舱轻量化设计与优化

方志凌1,2,宋燕利2(),康洁1,张杏红1,张丹1   

  1. 1.东风汽车集团有限公司研发总院,武汉 430056
    2.武汉理工大学,现代汽车零部件技术湖北省重点实验室,武汉 430070
  • 收稿日期:2023-12-05 修回日期:2024-01-28 出版日期:2024-07-25 发布日期:2024-07-22
  • 通讯作者: 宋燕利 E-mail:ylsong@whut.edu.cn
  • 基金资助:
    湖北省科技重大专项(2022AAA001);教育部创新团队发展计划(IRT_17R83);新能源汽车科学与关键技术学科创新引智基地项目(B17034);东风汽车集团有限公司十四五重大课题(下一代低碳智慧架构技术研究与应用)(91224Y22J521)

Lightweight Design and Optimization of Integrated Die Casting Aluminum Alloy Front Cabin

Zhiling Fang1,2,Yanli Song2(),Jie Kang1,Xinghong Zhang1,Dan Zhang1   

  1. 1.Dongfeng Motor Corporation Research & Development Institute,Wuhan  430056
    2.Wuhan University of Technology,Hubei Key Laboratory of Advanced Technology for Automotive Components,Wuhan  430070
  • Received:2023-12-05 Revised:2024-01-28 Online:2024-07-25 Published:2024-07-22
  • Contact: Yanli Song E-mail:ylsong@whut.edu.cn

摘要:

当前汽车行业对低碳化和轻量化的需求日益增长,新型一体化压铸技术应用于车身,能够实现质量、生产成本和周期的下降,并减少碳排放,成为各大汽车主机厂商争相研究热点。本文将某乘用车传统钢制车身前端机舱结构替换成一体化压铸件,对铝合金一体化前机舱进行了轻量化设计。通过SIMP法对前舱进行拓扑优化得到了最优刚度载荷路径,考虑前舱可铸造性对筋的拔模方向、厚度尺寸和位置分布进行设计。根据C-NCAP 2021进行正面碰撞仿真,通过田口实验设计方法与响应面优化改善了一体化压铸车身的耐撞性,并对优化后的白车身性能进行了仿真分析。与传统方案相比,一体化方案的质量减轻13.9%,白车身弯曲刚度提升9.7%,1阶模态达到要求。本文研究对后续一体化车身结构的平台化设计与工程应用具有指导意义。

关键词: 一体化压铸, 轻量化设计, 耐撞性, 前机舱

Abstract:

The requirement of low carbon and lightweight in the auto industry is growing now. The new mega-casting technology applied on vehicle body can better achieve weight, cost and emission reduction, and has become spotlight to automobile manufacturers. In this paper, the traditional steel front compartment of passenger car body is replaced by integrated die casting part, and lightweight design on the aluminum alloy integrated front engine compartment is conducted. The optimal load path for stiffness is obtained through topology optimization of the front cabin by SIMP method. Considering the castability of the front cabin, the draft direction, thickness size and position distribution of the ribs are designed. Frontal impact simulation is conducted according to C-NCAP2021 and the impact resistance of the integrated die cast body is improved through Taguchi experimental design method and response surface optimization. Simulation analysis is conducted on the optimized performance of the white body. Compared with the traditional scheme, the weight of the optimal design is reduced by 13.9%, with the bending stiffness of the BIW increased by 9.7%, and the first modal meets the requirements. The research in this paper is meaningful for the platform design and industrialized application of integrated die casting car body structure in the future.

Key words: integrated die casting, lightweight design, crashworthiness, front cabin