疲劳寿命计算在制动盘罩壳结构优化设计中的应用

Application of Fatigue Life Calculation in Optimum Structural Design of Brake Disc Shields

为解决某SUV车型在行驶过程中制动盘罩壳由于随机交变载荷激励引起的振动疲劳开裂问题,结合实际工程项目,基于Radioss的模态频率响应结果进行振动疲劳寿命数值模拟。结合仿真分析结果,提出一种"圆形凹坑"特殊结构改善制动盘罩壳安装孔局部区域刚度,达到结构优化目的。对比仿真分析及耐久试验结果表明,利用该分析方法不仅可以准确预测制动盘罩壳疲劳寿命薄弱区域,还可以利用"圆形凹坑"特殊结构提高部件刚度,起到结构优化设计的同时,还能大大减少项目开发成本,有效指导设计人员进行方案选定和问题整改。

To solve the fatigue damage problem of brake-disc splash shields of a particular SUV induced by random load excitation,their vibration-fatigue life is simulated based on Radioss modal frequency response results.According to the simulation results,a special structure called“round pit”is put forward for improving the local stiffness of mounting holes of the brake-disc splash shield for structure optimization.Comparison of the simulation results with fatigue testing results shows that the weak spots on the splash shield for fatigue life can be predicted accurately by using this method.Furthermore,the special structure“round pit”can be applied to increase the stiffness of components in order to optimize the structure design.Meanwhile,the project cost is efficiently reduced.