精密铸铝件一体化设计及在车身轻量化中的应用

doi:10.19562/j.chinasae.qcgc.2024.01.019

Abstract

Abstract:

The integrated precision casting technology of aluminum alloy is one of the important ways to achieve lightweight of automobiles. Firstly， lightweight aluminum alloy material， investment vacuum suction casting process， and topology optimization are adopted to carry out an integrated design of "material， process and structure" for the front subframe and dashboard crossbeam of the white body in this paper. Secondly， the weight， research and development cost， and development cycle of integrated aluminum alloy structural components are compared to the original steel components， which are significantly reduced. Finally， finite element simulation analysis and bench tests are conducted on the stiffness and modal of the white body with integrated precision cast aluminum parts. The results show that after the integrated design， the front subframe and dashboard crossbeam has reduced weight by 36.6% and 30.8% respectively， while the performance of the white body meets the design requirements.

Key words: precision casting, integrated design, lightweight, simulation analysis, bench test

Xianguang Gu, Honglin Chen, Luxin Yu, Daisheng Zhang. Integrated Design of Precision Aluminum Castings Parts and Its Application in Lightweight Vehicle Body[J].Automotive Engineering, 2024, 46(1): 179-186.

Figures/Tables 30

References 13

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Cu	Si	Mn	Ti	Be	Ca
4.90	0.03	0.40	0.21	<0.01	<0.01
Cd	Zr	Ga	V	Fe	AL
0.19	0.22	<0.01	0.18	0.02	余量

序号	制动工况A	倒车工况B	垂向工况C	转弯工况D	单轮跳动工况E
1	0.10	0.10	0.20	0.30	0.30
2	0.20	0.25	0.15	0.15	0.25
3	0.30	0.20	0.10	0.20	0.20
4	0.35	0.20	0.20	0.10	0.15

试验序号	试验因素					加权柔度值
试验序号	A	B	C	D	E	C（x）
1	0.1	0.1	0.2	0.3	0.3	0.094 5
2	0.111	0.278	0.167	0.167	0.278	0.084 5
3	0.125	0.25	0.125	0.25	0.25	0.091 2
4	0.133	0.267	0.267	0.133	0.2	0.110 8
5	0.25	0.125	0.188	0.25	0.188	0.111 2
6	0.211	0.263	0.211	0.105	0.211	0.099 8
7	0.174	0.174	0.174	0.261	0.217	0.068 2
8	0.211	0.211	0.109	0.158	0.316	0.112 1
9	0.353	0.118	0.118	0.118	0.294	0.092 7
10	0.24	0.2	0.16	0.16	0.24	0.103 6
11	0.3	0.2	0.2	0.15	0.15	0.099 3
12	0.261	0.174	0.13	0.261	0.174	0.097 5
13	0.35	0.1	0.2	0.15	0.2	0.112 8
14	0.304	0.217	0.087	0.261	0.13	0.099 2
15	0.318	0.182	0.136	0.091	0.273	0.089 5
16	0.292	0.167	0.167	0.167	0.208	0.105 2

铸铝件	振型描述	频率/Hz	设计目标频率/Hz
前副车架	1阶扭转	65.2	60
前副车架	1阶弯曲	205.0	180
仪表板横梁	1阶扭转	51.23	45
仪表板横梁	1阶弯曲	62.45	60

构件	振型描述	仿真频率/Hz	试验频率/Hz	设计目标频率/Hz
前副车架	1阶扭转	65.2	64.0	60
前副车架	1阶弯曲	205.0	199.1	180
仪表板横梁	1阶扭转	51.23	50.6	45
仪表板横梁	1阶弯曲	62.45	63.10	60

Integrated Design of Precision Aluminum Castings Parts and Its Application in Lightweight Vehicle Body

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Figures/Tables 30

References 13

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对比项	前副车架			仪表板横梁
对比项	精密铸铝件	钢制件	优化率	精密铸铝件	钢制件	优化率
质量/kg	10.2	16.1	36.6%	5.6	8.1	30.8%
零件数量	1	6	83.3%	1	24	95.8%

性能	加装钢制件白车身	加装精密铸铝件白车身	设计要求
弯曲刚度/（N·m^-1）	16 557.3	16 765.9	≥13 000
扭转刚度/（N·m·（°）^-1）	16 891.4	17 118.7	≥12 200

性能	加装钢制件白车身	加装精密铸铝件白车身	设计要求
1阶弯曲模态频率/Hz	49.66	52.94	≥50
1阶扭转模态频率/Hz	36.87	40.16	≥40

性能	试验	设计要求
弯曲刚度/（N·m^-1）	16 533.3	≥13 000
扭转刚度/（N·m·（°）^-1）	17 212.2	≥12 200
1阶弯曲模态频率/Hz	53.6	≥50
1阶扭转模态频率/Hz	41.2	≥40

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对比项	前副车架			仪表板横梁
对比项	精密铸铝件	钢制件	优化率	精密铸铝件	钢制件	优化率
模具数量/副	1	5	80.0%	1	21	95.2%
研发成本/万元	13.8	68	79.7%	28.8	512	94.4%
研制周期/天	90	280	67.8%	90	280	67.8%