重型车辆传动行动构件轻量化设计研究

Research on Lightweight Design of Heavy Vehicle Transmission and Action Components

重型车辆传动、行动构件数量多,采用铝合金轮毂轮辋代替原钢质构件能有效减少构件质量。针对高强铝合金韧性、弹性模量和疲劳强度低的问题,为满足其力学性能和保证安全性,在数值模拟和试验研究的基础上,建立构件性能、结构尺寸相匹配的等效静力韧度设计准则。在采用新制造工艺及成形方法使构件强度和韧性均提高的基础上应用该设计准则,结果表明新构件的静力韧度能达到原构件的水平。铝轮辋减重效果大于55%,铝轮毂减重大于60%,其安全系数为3.57,大于规定值3。经实际跑车验证,应用等效静力韧度设计准则设计的铝合金传动行动构件满足使用要求,解决了重型车辆轮毂轮辋采用高强铝合金替代同级别强度钢铁的瓶颈,为'以铝代钢'构件设计提供理论依据。

Heavy vehicle have a lot of transmission and action components,it can reduce weight of components effectively to use of aluminum hubs and rims instead of the original steel components.Due to toughness,elastic modulus and fatigue strength of high strength aluminum alloy is low,so it＇s a key problem that meets mechanical properties and ensure security.On the basis of the numerical simulation and experimental study,the design guidelines of equivalent static toughness are established that match material properties and structure dimensions.Research shows that using a new manufacturing process and forming method the structure,the strength and toughness of components is improved at the same time.The results show that the static toughness of new component can reach the level of the original components.Aluminum rim weight reduction is more than 55%,aluminum hub weight reduction is more than 60%,and its safety coefficient is 3.57,which is more than defined value 3.The test shows that the aluminum alloy transmission and action components can meet the requirements.The key issues are resolved that using high strength aluminum replaces steel for heavy vehicle hub and rim,at the same time,which provides a design theoretical foundation of ＂Aluminum instead of steel＂ for other vehicle component.