压铸镁合金轮状产品的结构优化设计

Optimized Structure Design of Die Casting Magnesium Alloy Wheel Products

以传动皮带轮为例,对压铸镁合金在轮状类产品中的材料替代技术和方法进行了研究。根据对轮状类产品的服役工况和失效形式分析,以及对原结构进行的应力分析和拓扑优化分析,重新设计了镁合金轮的结构。结果表明,镁合金轮服役应力从40.5MPa降低到24.7MPa,低于极限疲劳强度。与铝合金皮带轮相比,质量减轻了43.8%,材料成本减少了34.5%。

The substitution of die casting magnesium alloy for aluminum alloy in wheel products and its measures were analyzed by taking transmission pulley as a sample.Based on the analysis of service life and failure conditions,the structure of magnesium alloy transmission pulley was redesigned by the stress analysis of the original structure and topologic optimization analysis.The results reveal that service stress of the optimized magnesium alloy transmission pulley is decreased from 40.5MPa to 24.7MPa,greatly lower than ultimate fatigue strength.In addition,the absence of die casting defects in the pulley can be observed due to the realization of sequential solidification during filling process.Compared with those of aluminum alloy ones,the weight and cost of magnesium alloy transmission pulley are decreased by 43.8% and by 34.5%,respectively.