轻型客车后桥支撑结构设计及轻量化

Designand Lightweight of Rear Axle Support Structure for the Light Bus

为满足电动汽车安全和轻量化的设计需求,设计了由底盘纵梁、横梁和板簧支座相互榫接的一种框架式整体受力铝合金后桥支撑结构。通过静载试验,分析其结构强度和刚度,同时联合HyperWorks和ANSYS Workbench有限元软件建立该结构的有限元模型,并将试验结果与仿真结果对比,校核仿真模型。通过静态有限元分析,得到该结构在几种极限工况下的应力和变形云图,并根据分析结果,提出了该结构的轻量化设计方案。本次优化结果表明,在保证后桥支撑结构刚度和强度的同时,其质量减轻1.92kg,有效节省生产成本,简化工艺流程,为实际设计与制造提供了较好的参考。

In order to meet the design requirements of safety and lightweight of electric vehicle,a frame type aluminium alloy rear axle support structure of whole bearing which is formed by the means of joggle joint with automotive longitudinal beams,crossbeams and spring brackets was designed.A static load experiment was made on the rear axle support structure to analyse its structural strength and rigidity.At the same time,finite element model of the support structure was established by the combination of HyperWorks and ANAYS Workbench software.The results of the simulation analysis results were compared with the results of tests for the purpose of verifying the reliability of the simulation analysis models.Then the equivalent stress and total deformation of the structure under several extreme conditions were obtained by the static finite element analysis.Based on the results of finite element analysis,a lightweight design scheme for the structure was proposed.Optimization results indicate:in ensuring the rear axle support structure stiffness and strength at the same time,the quality is reduced by 1.92kg,which effectively saves the production cost,simplify the process and provides a good reference for the actual design and manufacture.