超高强度一体式侧围加强板热成形工艺与侧碰安全性分析

Hot forming process and side impact safety analysis of integrated ultra-high strength side wall reinforcing plate

为提高新能源电动汽车某车型侧围耐撞性及电池模组安全性,采用超高强度一体式侧围加强板结构,运用Autoform R8.0、LS-DYNA 971 R7软件,对超高强度一体式侧围加强板从热成形工艺、结构耐撞性进行设计分析。热成形分析中采用Autoform R8.0软件对复杂的不同板厚激光拼焊超高强度一体式侧围加强板成形过程中变薄、起皱等问题进行识别,通过型面优化等措施解决成形类问题发生。在耐撞性分析过程中,采用LS-DYNA 971 R7软件进行分析,充分体现超高强度一体式侧围加强板在控制侵入量和侵入速度的先进性,以低于最大侵入量标准47.5%的结果达到设计要求,同时发现在侧碰过程中电池模组顶部车身底板结构对电池模组上壳体会造成结构冲击,对电池模组安全性产生影响。文中通过仿真分析,实现超高强度一体式侧围加强板结构设计和耐撞性验证,既分析了在侧碰过程中驾驶员的安全,也分析了电池模组在侧碰过程中的安全性,提高电动汽车在碰撞过程中的整体安全水平,超高强度一体式侧围加强板被广泛应用于电动汽车。

In order to improve the crashworthiness of the side wall of a new energy electric vehicle model and the safety of the battery module,the ultra-high strength integrated side wall reinforcement plate structure is adopted.Autoform R8.0 and LSDYNA 971 R7 software are used to design and analyze the ultra-high strength integrated side wall reinforcement plate from the hot forming process and structural crashworthiness.In the hot forming analysis,Autoform R8.0 software is used to identify the problems such as thinning and wrinkling during the forming process of laser tailor welded ultra-high strength integrated side wall stiffening plates with different sheet thicknesses,and to solve the forming problems by means of surface optimization and other measures.In the process of crashworthiness analysis,LS-DYNA 971 R7 software is used for analysis,which fully reflects the progressiveness of the ultra-high strength integrated side wall reinforcement plate in controlling the intrusion volume and intrusion speed,and the result is 47.5%lower than the maximum intrusion volume standard to meet the design requirements.At the same time,it is found that in the process of side impact,the underbody structure at the top of the battery module will cause structural impact on the upper shell of the battery module,which will affect the safety of the battery module.Through simulation analysis,this paper realizes the structural design and crashworthiness verification of ultra-high strength integrated side wall reinforcement plate,which not only analyzes the driver’s safety in the side impact process,but also analyzes the safety of battery modules in the side impact process,so as to improve the overall safety level of electric vehicles in the collision process.The ultra-high strength integrated side wall reinforcement plate is widely used in electric vehicles.