Abstract:

For the complex thin-walled structure design of the integrated front engine compartment of electric vehicles， a structure and performance collaborative design method based on topology optimization is proposed in this paper. The optimal load path under multiple load conditions is determined through topology optimization and feasibility design of the front engine compartment integrated die-casting component process is conducted. Material testing is conducted on the die-cast materials， and failure surfaces are developed based on stress triaxiality and Lode angle coefficient stress states. A simplified frontal collision model is constructed to assess the stiffness compatibility between the extruded longitudinal beams and the die-cast components within the integrated front compartment structure. The results show that the proposed design method can effectively obtain topological paths under multiple performance constraints， fully consider the feasibility of the front cabin structure process and structural performance matching， and reduce research and development cost.

Key words: multi-performance topology optimization, front cabin integrated design, integrated die casting, fracture constitutive model