汽车工程 ›› 2024, Vol. 46 ›› Issue (12): 2154-2163.doi: 10.19562/j.chinasae.qcgc.2024.12.002

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一体压铸铝合金车身结构件的轻量化设计研究

刘波1,2,唐永鑫1,2,伍毅1,2(),王紫阳1,2,杨琴3,胡铁刚3,徐小敏3   

  1. 1.北京科技大学机械工程学院,北京 100083
    2.金属轻量化成形制造北京市重点实验室,北京 100083
    3.重庆长安汽车股份有限公司,重庆 401120
  • 收稿日期:2024-06-23 修回日期:2024-08-13 出版日期:2024-12-25 发布日期:2024-12-20
  • 通讯作者: 伍毅 E-mail:yi_wu@ustb.edu.cn
  • 基金资助:
    重庆市技术创新与应用发展重点专项(CSTB2022TIAD-DEX0011)

Study on Lightweight Design of Integrated Mega-casting Aluminum Alloy Vehicle Body Components

Bo Liu1,2,Yongxin Tang1,2,Yi Wu1,2(),Ziyang Wang1,2,Qin Yang3,Tiegang Hu3,Xiaomin Xu3   

  1. 1.School of Mechanical Engineering,University of Science and Technology Beijing,Beijing 100083
    2.Beijing Key Laboratory of Lightweight Metal Forming,Beijing 100083
    3.Chongqing Chang’an Automobile Co. ,Ltd. ,Chongqing 401120
  • Received:2024-06-23 Revised:2024-08-13 Online:2024-12-25 Published:2024-12-20
  • Contact: Yi Wu E-mail:yi_wu@ustb.edu.cn

摘要:

近年大型一体压铸铝合金车身结构件逐渐被用于取代传统的冲压-焊接白车身结构。本文以一体压铸的车身后地板结构为对象,开展了轻量化设计研究。针对一体压铸车身结构件的分析问题,提出了等效分析方法;考虑压铸结构的工艺与性能,研究了结构设计中的工艺约束,阐明了其材料性能的非均质性;基于拓扑优化方法,分析了该结构的设计域,获取了最优传力路径;在上述研究内容的基础上,开展了轻量化设计,在保证性能的同时实现了7%的轻量。相关研究工作明确了新型一体压铸铝合金车身结构件的设计优化流程,具有一定的参考和借鉴意义。

关键词: 车身轻量化, 铝合金一体压铸, 拓扑优化, 结构设计

Abstract:

In recent years, mega-casting aluminum alloy structures have gradually been used to replace traditional stamping-welded body-in-white structures. The study on lightweight design of mega-casting aluminum alloy rear floor structure is conduced in this paper. An equivalent analysis scheme is proposed for the analysis of mega-casting vehicle body components. Regarding the processing and performance of the mega-casting structure, the processing constraints for the design are investigated, and the heterogeneity of its material properties is clarified. Based on the topology optimization method, the design domain of the structure is analyzed and the ideal topological design is obtained. Finally, a lightweight design is carried out, achieving a 7% weight reduction while ensuring performance. The study illustrates the design and optimization process of the mega-casting vehicle body components, which has certain reference significance.

Key words: lightweight vehicle body, mega-casting aluminum alloy, topology optimization, structural design