基于数值仿真和动静态试验的副车架轻量化

Lightweight of subframe based on numerical simulation and dynamic and static tests

以某混凝土搅拌车副车架为研究对象,介绍一种合理可靠的轻量化设计研究方法,实现了副车架轻量化设计的预期目标。首先,应用Hyperworks软件建立了主副车架的数值仿真模型,对弯扭极限工况下副车架的静载强度进行仿真分析;通过静强度实车试验,验证了数值仿真模型的准确性。然后,根据体积最小化理论,应用Optistruct软件,优化副车架的结构厚度,并提出斜支撑加强板设计的新方案。最后,通过刚度特性的数值仿真,探究了轻量化后主副车架的刚度匹配性;并通过道路动态实车试验,测得副车架轻量化前后的载荷谱;利用Ncode 8.0软件处理,分析了道路载荷谱,结合高周疲劳寿命理论,对比研究了副车架的疲劳寿命。研究结果表明:轻量化方案具有良好的制造工艺继承性;静强度仿真与试验、刚度匹配性分析、动态疲劳试验相联合的研究方法,提升了副车架轻量化过程的科学性;最终使副车架的整体性能得到了改善,并实现减重120kg。

A reasonable and reliable lightweight design method was introduced to achieve the lightweight design of concrete truck mixer subframe. Firstly, Hyperworks software was applied to establish a numerical simulation model of concrete truck frame system, which was then used to simulate the system＇s ultimate bending and torsion conditions. Static strengths of real vehicle under different operation situations were obtained. Besides, static tests verified the accuracy of the simulation model. Secondly, the subframe thickness and stiffening plate structures were redesigned and the static strength of subframe was ensured by Optistruct software based on the accurate simulation model and the maximum volume theory. Finally, the frame system＇s stiffness match was also taken into the consideration. spectrum of subframe was measured to calculate Through vehicle dynamic tests, dynamic load the fatigue life of subframe with fatigue analysis theory and Ncode 8.0 software. The results show that the lightweight design shows good inheritance of manufacturing process. The method which combined the static strength analysis, the static frame stiffness match and the fatigue life comparison improves the scientificity of surface lightweight and achieves the lightweight goal of 120 kg reduction of subframe structures. Furthermore, the performances of the whole subframe are enhanced. 3 tabs, 13 figs, 16 refs.