变截面空心矩形前轴的设计及垂向、纵向工况性能的研究

doi:10.19562/j.chinasae.qcgc.2024.12.019

Abstract

Abstract:

The front axle manufactured through forging has large dimension， and the stress on it is complex. It is difficult to lightweight due to the limitation of the I-beam structure. In this paper， the design method of hollow front axle is given， and the hollow rectangular structure with variable cross-section and wall thickness and a combination of leaf spring seats are used to achieve lightweight and improve bending and torsion resistance. The influence of wall thickness at the kingpin hole on the strength of the fist is revealed， and the appropriate wall thickness range of the fist and the height and width coefficient of the plugging hole is given， by the vertical and longitudinal working conditions of the finite element mode. The 1：1 hollow front axle sample with an axle load of 5 t is produced by using seamless steel pipes， which is 10.75% lighter than the forged front axle. The variation law of vertical displacement and axial stress changes on the lower surface of the shaft and the stress distribution at the edge of the sealing hole on the outer end face of the fist are revealed through stiffness tests under vertical and longitudinal working conditions， as well as static strength and fatigue life tests under vertical working condition. The results show that the stiffness and static strength of the variable cross-section hollow rectangular front shaft meet industry standards， and the fatigue life under vertical working condition is much higher than industry standards. It is indicated that the variable cross-section hollow front axle can improve performance and achieve lightweight.

Key words: hollow rectangular front axle, design method, strength stiffness, fatigue life, bench test

Liandong Wang,Jinyu Li,Kai Feng,Yu Zhang,Ye Tian. Research on Design of Hollow Rectangular Front Axle with Variable Cross-section and Vertical and Longitudinal Performance Under Working Conditions[J].Automotive Engineering, 2024, 46(12): 2339-2354.

Figures/Tables 33

References 12

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A	1.2	1.3	1.4	1.5	1.6
t₄/mm	15.00	16.25	17.50	18.75	20.50
h₅/mm	58.0	55.0	50.0	50.0	44.5
b₅/mm	45.0	40.0	40.0	38.0	33.5

零件名称	前轴管件	其它	主销
材料	27Mn2	40Cr	20CrMo
密度ρ/（kg·m^-3）	7 850	7 850	7 870
弹性模量E/MPa	2.009×10⁵	2.090×10⁵	2.100×10⁵
泊松比μ	0.285	0.270	0.278
屈服极限σ_s/MPa	580	785	685
抗拉强度σ_b/MPa	647	980	885

A	1.2	1.3	1.4	1.5	1.6
σ_max/MPa	203.07	158.64	108.64	86.07	52.82
强度极限比率	25.27%	19.74%	13.52%	10.71%	6.57%

A	1.6	1.5	1.4	1.3	1.2
点i/MPa	2.71	10.73	13.70	37.02	73.40
点j/MPa	2.45	12.22	16.67	44.65	81.31
点k/MPa	8.06	16.24	22.30	46.45	81.52
点l/MPa	8.99	17.52	23.35	65.37	95.53
点m/MPa	8.47	14.84	39.22	45.99	61.39
点n/MPa	14.84	17.49	42.50	58.79	86.30

截面位置	项目	高度	宽度	壁厚
横梁中段	设计值/mm	115	93	12.5
横梁中段	实测值/mm	117.6	94.7	12.5
横梁中段两侧	设计值/mm	123	80	12.5
横梁中段两侧	实测值/mm	124.2	78.5	12.5
弯脖中部	设计值/mm	95	100	12
弯脖中部	实测值/mm	99.6	101.8	12.5
拳部主销孔	设计值/mm	93	88	20.5
拳部主销孔	实测值/mm	93.0	88.5	20.5

Research on Design of Hollow Rectangular Front Axle with Variable Cross-section and Vertical and Longitudinal Performance Under Working Conditions

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Figures/Tables 33

References 12

Related Articles 11

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试样切取位置	σ_s/MPa	Rm_条件/MPa	Rm_真实/MPa	δ/%
横梁中部	528.5	639.5	801.29	25.3
板簧座处	457.5	629.5	817.09	29.8
左右弯脖	462.3	635.3	803.65	26.5

点坐标	D₁	D₂	D₃	D₄
X/mm	0	-200	-310	-360
Y/mm	-57.51	-57.46	-57.43	-47.46
点坐标	D₅	D₆	D₈	D₉
X/mm	-460	-510	-765	-835
Y/mm	-47.44	-47.42	-124.68	-157.88

测量点	0°应变/με	45°应变/με	90°应变/με
U₁	-2 413.77	-935.37	259.00
U₂	-2 341.82	-1 247.56	329.00
U₃	-474.92	-31.27	337.90
D₁	2 253.81	730.86	-662.31
D₂	1 850.13	286.70	-1 072.31
D₃	2 426.83	1 183.62	-283.39
D₅	1 933.43	513.65	-708.00
D₆	1 694.71	222.63	-1 037.18
D₇	1 297.05	108.50	-1 128.74
D₈	993.14	508.86	-206.43
D₉	253.29	225.71	93.86

测量点	0°应变/με	45°应变/με	90°应变/με
a	-16.14	-8.10	-31.14
b	-52.58	-140.00	12.00
c	45.43	-334.86	-423.71
d	307.29	-195.86	-226.14
e	294.00	129.14	-251.00
f	216.43	194.14	-259.00
g	-14.00	199.14	-108.86
h	-52.57	140.00	18.86

测量点	a	b	c	d
σ_0°/MPa	-5.471	-10.749	-16.472	52.817
σ_90°/MPa	-7.82	-0.65	-89.82	-30.58
测量点	e	f	g	h
σ_0°/MPa	48.426	31.18	-9.907	-10.32
σ_90°/MPa	-36.62	-43.15	-24.89	0.85

测量点	a	b	c	d
模拟值/MPa	-5.56	-10.94	-16.528	53.79
相对误差/%	1.57	1.82	0.34	1.84
测量点	e	f	g	h
模拟值/MPa	48.921	32.36	-10.09	-10.03
相对误差/%	1.02	3.75	1.81	2.77

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