副车架静刚度修正方法及多层级拓扑优化

doi:10.19562/j.chinasae.qcgc.2023.11.017

Abstract

Abstract:

Based on the construction of the parallel simulation process of the static stiffness and K&C performance of the subframe， a correction method for static stiffness of subframe considering the coupling of performance is proposed， and a hierarchical design optimization method for the aluminum hollow subframe is systematically established. Firstly， a subframe calculation model is established and the loading method is improved， with a new static stiffness calculation method in a local coordinate system proposed. Three subcases including static stiffness analysis， flexibility model analysis and the K&C performance analysis are integrated and synchronously driven， and an ensembled surrogate model of K&C performance and static stiffness performance is constructed based on the multi-sample analysis and experimental design matrix conversion. The ensembled surrogate model is used to modify the static stiffness target according to the K&C performance index. Secondly， the multi-level topology optimization of the subframe under multi-performance constraints is carried out， using the first-level topology optimization to complete the main structure design with equal wall thickness， and the second-level topology optimization to complete the structure design with variable wall thickness. The results show that the first order and second order torsion modal increases by 39.3% and 14.9% respectively after multi-level topology optimization， with the static stiffness and K&C performance meeting the target requirements， on the premise of ensuring lighting-design and the other performance indicators significantly improved， which can provide a reference for the formulation of static stiffness performance targets of the subframe， the improvement of K&C performance and the optimization of the subframe structure.

Key words: subframe, static stiffness, K&C performance, topology optimization, multi-performance constraints

Yonglei Su,Zhifei Zhang. Correction Method of Static Stiffness and Multi-level Topology Optimization for Subframe[J].Automotive Engineering, 2023, 45(11): 2157-2164.

Figures/Tables 16

References 17

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实验序号	设计变量/mm				静刚度性能/（N·mm^-1）							K&C性能
实验序号	T₁	T₂	…	T_n	FUCA_k_x	FUCA_k_y	FUCA_k_z	…	SCA_k_x	SCA_k_y	SCA_k_z	加速度前束柔度（ATC）	…	制动前束柔度（BTC）
1	4.4	5.9	…	4.2	14 015	32 965	8 634	…	8 881	71 099	7 656	-0.019 0	…	-0.027 1
2	7.6	8.9	…	7.9	18 352	40 236	9 049	…	9 118	69 800	7 873	-0.021 2	…	-0.025 1
3	8.2	8.5	…	6.0	19 484	41 300	9 409	…	9 533	77 523	8 209	-0.020 2	…	-0.025 2
4	6.2	4.3	…	4.3	17 223	37 702	8 997	…	7 478	57 047	7 815	-0.023 3	…	-0.023 3
5	4.9	8.2	…	8.2	4 765	13 306	8 831	…	9 075	71 067	7 907	-0.022 3	…	-0.025 1
…	…	…	…	…	…	…	…	…	…	…	…	…	…	…
200	4.5	6.3	…	6.8	8 114	20 742	9 310	…	9 651	78 973	8 276	-0.023 2	…	-0.024 8

部分关键性能	PRSM	RBF	Kriging	Ensemble
ATC	0.94	0.98	0.99	0.99
BTC	0.93	0.97	0.95	0.98
LTC	0.95	0.96	0.97	0.99
LTC-a	0.92	0.96	0.98	0.99

Spearman	ATC	BTC	LTC	LTC-a
FLCA_t_x	0.028	-0.043	0.025	0.027
FLCA_t_y	0.011	0.008	0.063	0.059
FLCA_t_z	0.062	0.022	0.016	0.015
FUCA_t_x	0.087	0.035	0.046	0.045
FUCA_t_y	0.069	-0.006	0.027	0.025
FUCA_t_z	0.024	-0.006	-0.009	-0.01
RLCA_t_x	0.196	0.192	0.191	0.189
RLCA_t_y	0.829	0.886	0.905	0.904
RLCA_t_z	-0.044	-0.032	-0.029	-0.038
RUCA_t_x	0.038	0.022	0.024	0.025
RUCA_t_y	0.45	-0.377	-0.0274	-0.277
RUCA_t_z	0.05	0.043	0.056	0.055
SCA_t_x	0.024	0.041	0.058	0.057
SCA_t_y	-0.103	-0.012	0.087	0.089
SCA_t_z	0.033	0.003	0.001	0.002

静刚度类型	经验值/（kN·mm^-1）	修正值/（kN·mm^-1）
后上控制臂Y向	≥22	≥25
后下控制臂Y向	≥22	≥30

类型	工况定义	概念设计值	拓扑优化值	目标值
静刚度/ （kN·mm^-1）	前上控制臂Y向	20.7	22.7	≥22
	后上控制臂Y向	15.3	29.8	≥25
	后下控制臂Y向	20.2	30.1	≥30
	前下控制臂Y向	19.8	24.2	≥22
	前束臂Y向	33.8	36.2	≥25
模态/Hz	1阶扭转模态	122	170	≥170
	2阶扭转模态	148	170	≥170
	弯曲模态	222	245	≥220
等效静刚度/ （kN·mm^-1）	电机前悬置点	12.7	55.4	≥15
		27.1	157.7	≥30
		16.2	95.3	≥20
	电机后悬置点	63.4	34.9	≥30
		17.7	106	≥15
		18.1	63.5	≥30
	副车架前悬置点	16.4	20.0	≥15
		21.9	39.5	≥25
		6.88	7.12	≥7
	副车架后悬置点	56.8	79.2	≥25
		23.5	27.1	≥25
		6.0	12.9	≥7
质量/kg		25.1	24.4	≤24.5

Correction Method of Static Stiffness and Multi-level Topology Optimization for Subframe

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Figures/Tables 16

References 17

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K&C性能	概念设计值	拓扑优化值	目标值
ATC/（（°）·kN^-1）	-0.023	-0.019	［-0.02， -0.005］
BTC/（（°）·kN^-1）	-0.023 6	-0.023 4	［-0.12， -0.02］
LTC/（（°）·kN^-1）	0.15	0.17	［0.1， 0.2］
LTC-a/（mm·kN^-1）	-0.060	-0.059	［-0.09， -0.05］

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