拓扑优化在铝合金钳体优化中的应用

Application of Topology Optimization in Aluminum Alloy Clamp Body Optimization

以某SUV车型盘式制动器钳体为研究对象,从使用轻量化材料和结构优化两个方面对钳体进行了轻量化分析。首先,用CATIA建立了钳体的三维模型,在HyperWorks中建立了其仿真模型,并进行了刚度和强度分析,得到了其应力云图和位移云图。使用铸造铝合金材料对钳体进行了轻量化分析,发现其并不满足刚度要求后,对铝合金材质的钳体进行了尺寸改进,为了确定合理的改进尺寸,选取了5组尺寸数据并进行了建模和仿真对比;其次,基于变密度法,建立了钳体拓扑优化的数学模型,对钳体进行了拓扑优化,确定了铝合金材质钳体的合理结构,并在CATIA中重建了优化后的模型,对重建模型进行了静力分析,得到了优化后钳体的应力、位移云图,证明优化后的钳体满足刚、强度要求,且质量下降到原来的43%。最后,对原始钳体和最终优化钳体进行了疲劳寿命分析,验证了优化后钳体的合理性。

This paper carries out lightweight analysis of the caliper body considering lightweight materials and structure optimization in the study of disc brake caliper of a SUV vehicle.Firstly,the three-dimensional model of the clamp body is established by CATIA,and its simulation model is established in HyperWorks.The stiffness and strength analysis are carried out,and the stress and displacement nephogram are obtained.The casting aluminum alloy material was used to lightweight the clamp body.Size of the clamp body made of aluminum alloy material was improved.In order to determine the reasonable improved size,five groups of size data were selected and compared for modeling and simulation.Secondly,based on the variable density method,the mathematical model of the clamp body topology optimization is established,and the reasonable structure of the clamp body made of aluminum alloy is determined.The optimized model is reconstructed in CATIA.The static analysis of the reconstructed model is carried out,and the stress and displacement nephogram of the optimized clamp body are obtained.It is proved that the optimized clamp body meets the requirements of rigidity and strength,and the quality of the clamp body is good.The weight went down to 43%.Finally,the fatigue life of the original clamp body and the final optimized clamp body is analyzed,and the rationality of the optimized clamp body is verified.