一体压铸铝合金车身结构件的轻量化设计研究

doi:10.19562/j.chinasae.qcgc.2024.12.002

Abstract

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

Bo Liu,Yongxin Tang,Yi Wu,Ziyang Wang,Qin Yang,Tiegang Hu,Xiaomin Xu. Study on Lightweight Design of Integrated Mega-casting Aluminum Alloy Vehicle Body Components[J].Automotive Engineering, 2024, 46(12): 2154-2163.

Figures/Tables 34

材料	弹性模量E/GPa	泊松比	密度/（t· $m m - 3$ ）
一体压铸铝合金	65	0.33	2.63× $10 - 9$
钢材	210	0.30	7.85× $10 - 9$
粘胶	2	0.41	1.07× $10 - 9$

方案	弯曲工况权重系数 $ω 1$	扭转工况权重系数 $ω 2$
1	0.6	0.4
2	0.5	0.5
3	0.4	0.6
4	0.25	0.75
5	0.15	0.85

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厚度 t/mm	弹性模量 E/GPa	屈服拉伸强度R_p0.2/MPa	极限拉伸强度R_m/MPa	断后延伸率A/%
2	63.20	139-140	233-272	5-10
3	63.98	142-144	266-281	8-11
4	65.64	120-131	239-260	8-11
5	66.40	116-120	192-239	4-7

模态阶次	频率/Hz	振型
1阶	31.68	1阶扭转
2阶	91.19	1阶弯曲
3阶	97.07	局部模态
4阶	150.46	1阶横摆
5阶	158.53	2阶弯曲
6阶	164.88	2阶扭转

工况	加载点	位移/mm	刚度
弯曲	①	-3.07	1 318.26 N/mm
弯曲	②	-3.11	1 318.26 N/mm
扭转	①	+8.25	9 426.65 N·m/（°）
扭转	②	-8.31	9 426.65 N·m/（°）

方案	弯曲工况柔度/（N?mm）	扭转工况柔度/（N?mm）	相对变化/%
1	7 811.8	18 711.5	-71.6
2	8 032.4	18 562.0	-70.3
3	8 211.0	18 172.0	-70.2
4	7 452.4	19 471.9	-72.0
5	8 705.7	17 836.9	-67.2

工况	加载点	位移/mm	刚度
弯曲	①	-2.89	1 402.06 N/mm
弯曲	②	-2.93	1 402.06 N/mm
扭转	①	+8.29	9 411.96 N·m/（°）
扭转	②	-8.32	9 411.96 N·m/（°）

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

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Figures/Tables 34

References 23

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模态阶次	频率/Hz	振型	较原始结构变化量/Hz
1阶	34.22	1阶扭转	+2.54
2阶	99.22	1阶弯曲	+8.03
3阶	117.96	局部模态	+20.89
4阶	162.55	1阶横摆	+12.09
5阶	168.16	2阶弯曲	+9.63
6阶	195.65	2阶扭转	+30.77

项目	单位	优化前	优化后	变化率
质量	kg	49.97	46.46	↓7.0%
弯曲刚度	N/mm	1 318.26	1 402.06	↑6.0%
扭转刚度	N·m/（°）	9 426.65	9 411.96	↓0.2%
1阶模态	Hz	31.68	34.22	↑8.0%

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