基于挤压成形再冲压工艺的后悬弹簧连杆轻量化设计方法

Lightweight design method on rear suspension spring connecting rod based on extrusion and stamping process

传统后悬弹簧连杆制造工艺繁多,且在实际工作过程中的耐久性和强度等性能表现并不佳。通过引用新型铝合金材料,以挤压成形为冲压毛坯成形工艺,并结合成熟的冲压工艺,取消了电泳后处理工艺,而且重新设计了零件结构,从而设计出新型铝镁硅可热处理强化合金的后悬弹簧连杆。通过有限元模拟分析进行初步设计,并利用试验车以及台架试验验证有限元模拟分析的准确性和设计思路的可行性。结果表明:新设计有较好的可制造性,其重量相比原冲压焊接设计减少了40%,强度性能提高了38%,刚度性能接近原钢件设计。无焊接变形的新工艺明显减少了四轮定位参数的变化量,提高了轮胎使用寿命,而且悬架整体硬点不变,且成本略有减低。

There are too many manufacturing processes for the traditional rear suspension spring connecting rod,and the performances of durability and strength in the actual working process are not good.Therefore,a new rear suspension spring connecting rod of aluminum-magnesium-silicon heat-treatable and strengthened alloy was designed by quoting new aluminum alloy material,using extrusion process as stamping blank forming process,combining with mature stamping process,canceling the electrophoretic post-treatment process and redesigning part structure.Then,the initial design was conducted by the finite element simulation analysis,and the accuracy of finite element simulation analysis and the feasibility of new design were verified by the vehicle testing and bench test.The results show that the new design has good manufacturability,the weight reduces by 40%compared with the original stamping and welding design,the strength performance improves by 38%,and the stiffness performance is close to that of the original steel part.Thus,the new process without welding deformation obviously reduces the variation of four-wheel alignment parameters and improves the service life of tire.In addition,the overall hard point of suspension remains unchanged,and the cost is slightly reduced.