汽车工程 ›› 2023, Vol. 45 ›› Issue (7): 1263-1275.doi: 10.19562/j.chinasae.qcgc.2023.07.017
所属专题: 车身设计&轻量化&安全专题2023年
收稿日期:
2022-11-29
修回日期:
2023-01-17
出版日期:
2023-07-25
发布日期:
2023-07-25
通讯作者:
曾维和
E-mail:weihe.zeng@geely.com
Weihe Zeng(),Ligang Gou,Yu Luo,Jun Zhang,Huihong Liao
Received:
2022-11-29
Revised:
2023-01-17
Online:
2023-07-25
Published:
2023-07-25
Contact:
Weihe Zeng
E-mail:weihe.zeng@geely.com
摘要:
针对某车型一体压铸铝合金超大尺寸后段车身耐久开发问题,测试了压铸车身用铸态铝合金应变-寿命(E-N)数据,并对疲劳试样实测数据拟合得到合金E-N曲线关键参数;搭建Trim Body有限元模型,基于模态瞬态法计算了压铸车身应力动态响应,对应力时程响应信号雨流统计,结合实测拟合的E-N曲线和Miner损伤累积原理,对比分析了车身初始设计和优化设计方案的疲劳损伤;最后将优化设计的一体压铸件装车进行整车四立柱强化耐久测试。研究结果表明:压铸铝合金E-N关系曲线可用Manson-Coffin-Basquin方程描述;与初始方案比,改进设计的一体压铸铝合金车身最大损伤由2.67降低至0.32,疲劳开裂风险消除,经四立柱强化耐久试验验证一体压铸铝车身未见开裂。研究成果可为一体压铸铝合金车身达成耐久属性开发目标提供参考依据。
曾维和, 苟黎刚, 罗宇, 张俊, 廖慧红. 超大尺寸一体式压铸铝合金后段车身疲劳仿真与试验研究[J]. 汽车工程, 2023, 45(7): 1263-1275.
Weihe Zeng, Ligang Gou, Yu Luo, Jun Zhang, Huihong Liao. Fatigue Simulation and Experimental Study of Super-size Integral Die Casting Aluminum Alloy Rear End Body[J]. Automotive Engineering, 2023, 45(7): 1263-1275.
1 | 刘付曙, 廖仲杰, 陈国恩,等. 高真空压铸减震塔铸件力学性能的研究[J]. 特种铸造及有色合金, 2022, 42(2): 246-248. |
LIU F S, LIAO Z J, CHEN G E, et al. Mechanical properties of high vacuum die casting shock tower parts[J]. Special Casting & Nonferrous Alloys, 2022, 42(2): 246-248. | |
2 | FRANKE R, DRAGULIN D, ZOVI A, et al. Progress in ductile aluminum high pressure die casting alloys for the automotive industry[J]. Die Casting, 2017: 101-105. |
3 | NIKLAS A, BAKEDANO A, ORDEN S, et al. Microstructure and mechanical properties of a new secondary AlSi10MnMg(Fe) alloy for ductile high pressure die casting parts for the automotive industry[J]. Key Engineering Materials, 2016, 710: 244-249. |
4 | 王万林, 徐从昌, 王震虎, 等. 铝合金车体的有限元分析和结构评估方法研究[J]. 汽车工程, 2019, 41(6): 607-614. |
WAND W L, XU C C, WANG Z H, et al. A study on finite element analysis and structural assessment method for aluminum alloy vehicle body[J]. Automotive Engineering, 2019, 41(6): 607-614. | |
5 | 张俊超, 钟鼓, 邹纯, 等. 真空压铸铝合金减震塔缺陷分析及改进[J]. 特种铸造及有色合金, 2019, 39(3): 275-278. |
ZHANG J C, ZHONG G, ZOU C, et al. Casting defects analysis and quality improvement of aluminum alloy shock towers fabricated by vacuum assisted high pressure die casting[J]. Special Casting & Nonferrous Alloys, 2019, 39(3): 275-278. | |
6 | WANG Qigui, JONES Peggy. Fatigue behavior and life prediction for aluminum castings in the absence of casting flaws[C]. SAE Paper 2011-01-0193. |
7 | SPANGENBERGER A G, LADOS D A, COLEMAN M, et al. Microstructure and advanced characterization of long and small fatigue crack growth in cast A356-T6 aluminum alloys[J]. International Journal of Fatigue, 2017, 97: 202-209. |
8 | 张俊超, 钟鼓, 邹纯, 等. 高真空压铸铝合金的研究进展[J]. 材料导报, 2018, 32(32): 375-378. |
ZHANG J C, ZHONG G, ZOU C, et al. Research progress of the high vacuum die casting aluminum alloys[J]. Materials Reports, 2018, 32(32): 375-378. | |
9 | 段宏强,韩志勇, 王斌. 汽车结构件用非热处理压铸铝合金研究进展[J]. 汽车工艺与材料, 2022 (5): 1-6. |
DUAN H Q, HAN Z Y, WANG B. Research progress on non-heat treatment die casting aluminum alloy for automotive structural parts[J]. Automobile Technology & Materials, 2022(5): 1-6. | |
10 | 汪学阳, 黄志恒, 廖仲杰, 等. 高真空压铸铝合金减震塔工艺开发及应用[J]. 特种铸造及有色合金, 2018, 38(8): 860-863. |
WANG X Y, HUANG Z H, LIAO Z J, et al. Application and development of high vacuum die casting progress for aluminum alloy shock tower[J]. Special Casting & Nonferrous Alloys, 2018, 38(8): 860-863. | |
11 | 刘金水, 雷横兵, 高文理, 等. 铸造残余应力对铝合金副车架疲劳寿命的影响[J]. 湖南大学学报(自然科学版), 2018, 45(6): 28-34. |
LIU J S, LEI H B, GAO W L, et al. Effect of casting residual stress on fatigue life of aluminum alloy subframe[J]. Journal of Hunan University(Natural Science), 2018, 45(6): 28-34. | |
12 | 陶永亮, 娄梦妮. 新能源汽车销量促进压铸产业及一体化压铸发展[J]. 铸造设备与工艺, 2022,15(2): 52-55. |
TAO Y L, LOU M N. Sales of new energy vehicles promote the development of die casting industry and integrated die casting[J]. Foundry Equipment and Technology, 2022, 15(2): 52-55. | |
13 | 林佳武, 李玄霜,陈宗明, 等. 真空高压铸造铝合金车身后纵梁轻量化设计[J]. 汽车工程, 2020, 42(3): 383-400. |
LIN J W, LI X S, CHEN Z M, et al. Lightweight design of body rear longitudinal beam of VAHP die casting aluminum alloy[J]. Automotive Engineering, 2020, 42(3): 383-400. | |
14 | 潜圣文, 郑德兵. 基于高压薄壁铸铝的车身前轮罩成形技术研究[J]. 模具工业, 2021, 47(5): 67-71. |
QIAN S W, ZHENG D B. Study on formability of front wheel housing based on thin-wall HPDC aluminum[J]. Die & Mould Industry, 2021, 47(5): 67-71. | |
15 | 陈学美, 朱仁举. 铝合金后轮罩真空压铸工艺优化设计[J]. 铸造, 2017, 66(9): 952-957. |
CHEN X M, ZHU R J. Optimization design of vacuum die casting process of aluminum alloy rear wheel cowl[J]. Foundry, 2017, 66(9): 952-957. | |
16 | 聂小勇, 杨海, 李慎国, 等. 真空压铸铝合金减震塔在铝车身上的应用[J]. 特种铸造及有色合金, 2020, 40(3): 286-290. |
NIE X Y, YANG H, LI S G, et al. Application of vacuum die aluminum shock tower casting in vehicle body[J]. Special Casting & Nonferrous Alloys, 2020, 40(3): 286-290. | |
17 | 王春涛, 姚杰. 压铸铝合金的研究进展[J]. 模具工业, 2019, 45(8): 1-5. |
WANG C T, YAO J. Research progress of die casting aluminum alloy[J]. Die & Mould Industry, 2019, 45(8): 1-5. | |
18 | FABRIZI A, FERRARO S, TIMELLI G. The influence of Sr, Mg and Cu addition on the microstructural properties of a secondary AlSi9Cu3(Fe) die casting alloy[J]. Materials Characterization, 2013, 85: 13-16. |
19 | 胡祖麒, 万里, 吴晗, 等. 高强韧压铸Al-Mg-Si-Mn合金的微观组织及力学性能[J]. 中国有色金属学报, 2013, 23(3): 616-621. |
HU Z Q, WAN L, WU H, et al. Microstructure and mechanical properties of high strength and toughness die casting Al-Mg-Si-Mn alloys[J]. The Chinese Journal of Nonferrous Metals, 2013, 23(3):616-621. | |
20 | 车欣, 马思图, 陈立佳, 等. Er元素对Al-Si-Cu-Mg合金的显微组织及其低周疲劳行为的影响[J]. 热加工工艺, 2017, 46(16): 234-237. |
CHE X, MA S T, CHEN L J, et al. Effects of rare earth Er on microstructure and low-cycle fatigue behavior of Al-Si-Cu-Mg alloy[J]. Hot Working Technology, 2017, 46(16): 234-237. | |
21 | 李锋, 单飞虎, 车欣, 等. AS41压铸镁合金的低周疲劳行为[J]. 沈阳工业大学学报, 2011, 33(5): 510-515. |
LI F, SHAN F H, CHE X, et al. Low-cycle behavior of die-cast AS41 magnesium alloy[J]. Journal of Shenyang University of Technology, 2011, 35(5): 510-515. | |
22 | 金一, 柳进, 甄彤, 等. 底盘控制臂用800MPa级高强度钢的疲劳特性研究[J]. 上海金属, 2021, 43(6): 47-51. |
JIN Y, LIU J, ZHEN T, et al. Research on fatigue behavior of 800MPa grade high strength steel used for chassis control arm[J]. Shanghai Metals, 2021, 43(6): 47-51. | |
23 | 张海阳,金一, 张梅. 异种铝合金角接接头低周疲劳特性试验研究[J]. 上海金属, 2020, 42(5): 27-31. |
ZHANG H Y, JIN Y, ZHANG M. Experimental study on low cycle fatigue characteristics of T-joint of dissimilar aluminum alloy[J]. Shanghai Metals, 2020, 42(5): 27-31. | |
24 | 车欣, 梁兴奎, 陈丽丽, 等. Al-9.0%Si-4.0%Cu-0.4%Mg(-0.3%Sc)合金的显微组织及其低周疲劳行为[J]. 金属学报, 2014, 50(9): 1046-1054. |
CHE X, LIANG X K, CHEN L L, et al. Microstructure and low-cycle fatigue behavior of Al-9.0%Si-4.0%Cu-0.4%Mg(-0.3%Sc) alloy[J]. ACTA Metallurgica Sinica, 2014, 50(9): 1046-1054. | |
25 | 车欣, 徐志军, 陈立佳, 等. Al-Si-Cu-Mg (-Er)铸造铝合金的低周疲劳行为[J]. 铸造, 2011, 60(1): 20-23. |
CHE X, XU Z J, CHEN L J, et al. Low-cycle fatigue behavior of cast Al-Si-Cu-Mg (-Er) aluminum alloy[J]. Foundry, 2011, 60(1): 20-23 | |
26 | 荣兵, 肖攀, 周建文. 基于实测载荷谱和仿真载荷谱的底盘疲劳分析及对比[J]. 振动与冲击, 2018, 37(12): 179-186. |
RONG B, XIAO P, ZHOU J W. A fatigue comparative analysis of chassis based on simulated road load spectrum and measured road load spectrum[J]. Journal of Vibration and Shock, 2018, 37(12): 179-186. | |
27 | 范璐, 陈伟波, 刘立刚. 基于虚拟载荷的悬架台架耐久试验方法[J]. 汽车工程, 2019, 41(9): 1080-1087. |
FAN L, CHEN W B, LIU L G. A bench test method for suspension durability based on virtual load[J]. Automotive Engineering, 2019, 41(9): 1080-1087. | |
28 | TASCI M, TEBBE J, DAVIS J. Development of 3-D digital proving ground profiles for use in virtual prediction of vehicle system/ sub-system loads[C]. SAE Paper 2011-01-0189. |
29 | SCHUDT J, KODALI R, SHAH M. Virtual road load data acquisition in practice at general motors[C]. SAE Paper 2011-01-0025. |
30 | 耿动梁, 高丰岭, 卜晓兵, 等. 基于CDTire的车辆动态载荷提取方法[J].汽车技术, 2022 (4): 16-22. |
GENG D L, GAO F L, BU X B, et al. Extraction method of vehicle dynamic load based on CDTire[J]. Automobile Technology, 2022 (4): 16-22. | |
31 | 方吉,兆文忠, 朴明伟. 基于模态叠加法的焊接结构疲劳寿命预测方法研究[J]. 振动与冲击, 2015, 34(5): 186-192. |
FANG J, ZHAO W Z, PU M W. Fatigue life prediction of welded structures based on modal superposition method[J]. Journal of Vibration and Shock, 2015, 34(5): 186-192. | |
32 | 宋庆伟, 张晶, 王晗. 基于模态应力的转向架关键悬挂件振动疲劳分析[J]. 机车电传动, 2018 (5): 42-45. |
SONG Q W, ZHANG J, WANG H. Vibration fatigue of key suspension parts of bogies based on modal stress[J]. Electric Drive for Locomotives, 2018 (5): 42-45. | |
33 | 王玮, 周肖飞. 基于模态应力法的副车架疲劳分析研究[J]. 机械制造与自动化, 2020 (3): 127-129. |
WANG W, ZHOU X F. Subframe fatigue analysis based on modal coordinate[J]. Machine Building & Automation, 2020 (3): 127-129. | |
34 | 黄力平. 汽车结构的耐久性—理论与实践[M]. 北京:机械工业出版社, 2020. |
HUANG L P. Automotive structure durability-principle and practice[M]. Beijing: China Machine Press, 2020. |
No related articles found! |
|