Abstract:

Aluminum alloy integrated die-casting technology is an important means to achieve automotive lightweight. In this paper， structure optimization， molding simulation technology， die-casting technology are adopted for "material-structure-process" integrated design and manufacture of shock tower. Firstly， combined with extensive design experience， the three-dimensional data of the shock tower is determined through performance objectives， material selection and structural design. Subsequently， the performance analysis of the shock tower is conducted to ensure that the performance objectives are met， and the mold flow analysis of the temperature and velocity fields is conducted based on the designed mold structure， and optimization measures are proposed. Finally， the parts trial production is carried out to conclude problems and analyze causes， and propose solutions to form the shock tower development process. The study shows that the weight reduction rate of the shock tower reaches 16.5% while meeting the requirements of various performance indexes. The integrated design method is feasible， provides the industry with the ability to analyze the whole process and actual production experience， and enhances the confidence of manufacturers in adopting integrated die-casting technology.

Key words: integrated die casting, lightweight, simulation analysis, mold design, body-in-white