基于OptiStruct的驱动桥壳轻量化设计

Lightweight Design of Drive Axle Housing based on OptiStruct

驱动桥壳作为汽车的重要承载部件,必须满足刚度和强度的要求,传统的设计理念为了保证性能需求,一般采用冗余设计。通过CAD/CAE的一体化建模技术,采用三维数学模型与有限元模型之间的联合设计,基于OptiStruct的尺寸优化算法实现驱动桥壳的轻量化设计。利用CATIA创建驱动桥壳三维数学模型,导入HYPERMESH力学、动力学分析、疲劳分析验证驱动桥壳满足使用标准,再在OptiStruct求解器做优化分析,经过多次迭代计算,得到分析结果。优化后的桥壳成质量为152. 042 kg,减少了50. 075 kg,减重达到24. 78%,然后对优化后驱动桥壳进行分析,最后对试制的优化后桥壳进行疲劳台架试验,分析和试验结果表明,优化后桥壳满足试验标准,对同类型的轻量化设计有一定的参考价值。

As an important part of automobile,the lightweight design of the driving axle housing must be carried out to meet the requirements of its stiffness and strength. In order to ensure the performance requirements,the traditional design concept generally adopts redundant design. Based on the integrated technology of CAD/CAE,the joint design between 3D mathematical model and finite element model is adopted,and the lightweight design of the driving axle housing is realized based on the size optimization algorithm of OptiStruct. The drive axle housing model created by CATIA is introduced into HYPERMESH for pre-processing,the calculation conditions and boundary conditions are designed and proposed. The statics,dynamics analysis and fatigue analysis are used to verify that the drive axle housing meets the use standard. Then the optimization analysis is conducted in the OptiStruct solver,and several iterative calculations are used to get the analysis result. The mass of the optimized axle housing is 152.042 kg,which is reduced by 50.075 kg,and the weight loss reaches 24.78%,and then the optimized drive axle housing is analyzed. Finally,the fatigue bench test of the optimized axle housing is carried out. The analysis and experimental results show that the optimized axle housing meets the test standard and a certain reference value for lightweight design of the same type is provided.