一体化压铸铝合金前机舱轻量化设计与优化

doi:10.19562/j.chinasae.qcgc.2024.07.018

Abstract

Abstract:

The requirement of low carbon and lightweight in the auto industry is growing now. The new mega-casting technology applied on vehicle body can better achieve weight， cost and emission reduction， and has become spotlight to automobile manufacturers. In this paper， the traditional steel front compartment of passenger car body is replaced by integrated die casting part， and lightweight design on the aluminum alloy integrated front engine compartment is conducted. The optimal load path for stiffness is obtained through topology optimization of the front cabin by SIMP method. Considering the castability of the front cabin， the draft direction， thickness size and position distribution of the ribs are designed. Frontal impact simulation is conducted according to C-NCAP2021 and the impact resistance of the integrated die cast body is improved through Taguchi experimental design method and response surface optimization. Simulation analysis is conducted on the optimized performance of the white body. Compared with the traditional scheme， the weight of the optimal design is reduced by 13.9%， with the bending stiffness of the BIW increased by 9.7%， and the first modal meets the requirements. The research in this paper is meaningful for the platform design and industrialized application of integrated die casting car body structure in the future.

Key words: integrated die casting, lightweight design, crashworthiness, front cabin

Zhiling Fang,Yanli Song,Jie Kang,Xinghong Zhang,Dan Zhang. Lightweight Design and Optimization of Integrated Die Casting Aluminum Alloy Front Cabin[J].Automotive Engineering, 2024, 46(7): 1314-1322.

Figures/Tables 17

References 27

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序号	t₁/mm	t₂/mm	t₃/mm	t₄/mm	t₅/mm	t₆/mm
1	3	4	5	6	1.2	1.2
2	3	4	5	6	1.2	1.4
3	3	5	3	4	1.8	1.6
4	3	6	4	3	1.6	1.8
5	3	3	6	5	1.4	1.2
6	4	3	3	6	1.6	1.2
7	4	4	4	4	1.4	1.2
8	4	5	6	3	1.2	1.4
9	4	6	3	5	1.2	1.6
10	4	3	5	3	1.8	1.8
11	5	3	6	4	1.2	1.8
12	5	4	3	3	1.8	1.2
13	5	5	5	5	1.6	1.2
14	5	6	3	3	1.4	1.4
15	5	3	4	6	1.2	1.6
16	6	4	5	3	1.4	1.6
17	6	4	3	5	1.2	1.8
18	6	5	4	3	1.2	1.2
19	6	6	6	6	1.8	1.2
20	6	3	3	4	1.6	1.4
21	3	3	4	5	1.8	1.4
22	3	4	6	3	1.6	1.6
23	3	5	3	6	1.4	1.8
24	6	6	5	4	1.2	1.2
25	6	6	6	6	1.8	1.2

指标	优化前	优化后	提升
S₁/mm	82.7	22.0	-73.40%
S₂/mm	102.8	75.0	-27.04%
S₃/mm	114.6	54.3	-52.62%
a	11.9g	14.1g	+18.49%
S_M/mm	127.7	87.4	-31.56%
m/kg	40.910	41.345	+1.06%

指标	钣金方案	一体化方案	提升
扭转刚度/（N·m·（°）^-1）	23 082	22 957	-0.5%
弯曲刚度/（N·mm^-1）	20 833	22 857	+9.7%
1阶扭转模态/Hz	38.8	40.1	+3.4%
1阶弯曲模态/Hz	40.5	39.8	-1.7%
质量/kg	48	41.35	-13.9%

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Lightweight Design and Optimization of Integrated Die Casting Aluminum Alloy Front Cabin

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Figures/Tables 17

References 27

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序号	t₁/mm	t₂/mm	t₃/mm	t₄/mm	t₅/mm	t₆/mm
1	3	4	5	6	1.2	1.2
2	3	4	5	6	1.2	1.4
3	3	5	3	4	1.8	1.6
4	3	6	4	3	1.6	1.8
5	3	3	6	5	1.4	1.2
6	4	3	3	6	1.6	1.2
7	4	4	4	4	1.4	1.2
8	4	5	6	3	1.2	1.4
9	4	6	3	5	1.2	1.6
10	4	3	5	3	1.8	1.8
11	5	3	6	4	1.2	1.8
12	5	4	3	3	1.8	1.2
13	5	5	5	5	1.6	1.2
14	5	6	3	3	1.4	1.4
15	5	3	4	6	1.2	1.6
16	6	4	5	3	1.4	1.6
17	6	4	3	5	1.2	1.8
18	6	5	4	3	1.2	1.2
19	6	6	6	6	1.8	1.2
20	6	3	3	4	1.6	1.4
21	3	3	4	5	1.8	1.4
22	3	4	6	3	1.6	1.6
23	3	5	3	6	1.4	1.8
24	6	6	5	4	1.2	1.2
25	6	6	6	6	1.8	1.2

序号	t₁/mm	t₂/mm	t₃/mm	t₄/mm	t₅/mm	t₆/mm
1	3	4	5	6	1.2	1.2
2	3	4	5	6	1.2	1.4
3	3	5	3	4	1.8	1.6
4	3	6	4	3	1.6	1.8
5	3	3	6	5	1.4	1.2
6	4	3	3	6	1.6	1.2
7	4	4	4	4	1.4	1.2
8	4	5	6	3	1.2	1.4
9	4	6	3	5	1.2	1.6
10	4	3	5	3	1.8	1.8
11	5	3	6	4	1.2	1.8
12	5	4	3	3	1.8	1.2
13	5	5	5	5	1.6	1.2
14	5	6	3	3	1.4	1.4
15	5	3	4	6	1.2	1.6
16	6	4	5	3	1.4	1.6
17	6	4	3	5	1.2	1.8
18	6	5	4	3	1.2	1.2
19	6	6	6	6	1.8	1.2
20	6	3	3	4	1.6	1.4
21	3	3	4	5	1.8	1.4
22	3	4	6	3	1.6	1.6
23	3	5	3	6	1.4	1.8
24	6	6	5	4	1.2	1.2
25	6	6	6	6	1.8	1.2

序号	t₁/mm	t₂/mm	t₃/mm	t₄/mm	t₅/mm	t₆/mm
1	3	4	5	6	1.2	1.2
2	3	4	5	6	1.2	1.4
3	3	5	3	4	1.8	1.6
4	3	6	4	3	1.6	1.8
5	3	3	6	5	1.4	1.2
6	4	3	3	6	1.6	1.2
7	4	4	4	4	1.4	1.2
8	4	5	6	3	1.2	1.4
9	4	6	3	5	1.2	1.6
10	4	3	5	3	1.8	1.8
11	5	3	6	4	1.2	1.8
12	5	4	3	3	1.8	1.2
13	5	5	5	5	1.6	1.2
14	5	6	3	3	1.4	1.4
15	5	3	4	6	1.2	1.6
16	6	4	5	3	1.4	1.6
17	6	4	3	5	1.2	1.8
18	6	5	4	3	1.2	1.2
19	6	6	6	6	1.8	1.2
20	6	3	3	4	1.6	1.4
21	3	3	4	5	1.8	1.4
22	3	4	6	3	1.6	1.6
23	3	5	3	6	1.4	1.8
24	6	6	5	4	1.2	1.2
25	6	6	6	6	1.8	1.2