某电动车铝转向节台架失效分析及优化

Bench Test Failure Analysis and Optimization of Aluminum Knuckle of an Electric Vehicle

针对某电动车铝材转向节在台架试验中出现裂纹失效问题,开展了失效分析研究。通过失效件的检查,以及对标零件的分析,确定了失效原因;进行了设计优化,通过计算机辅助工程分析以及台架试验及道路试验验证了优化方案的可靠性。结果表明,优化后,零件应力最大值降低了超过30%,疲劳寿命得到较大提高。铝合金产品由于机械性能相对于铸铁件较弱,产生应力集中对零件的疲劳寿命产生影响更大。在铸铝件零件设计的时候,应保证零件曲面结构光滑过渡。

Aiming at the failure of aluminum steering knuckle of an electric vehicle in bench test,failure analysis and research were carried out.Through the inspection of the failed parts and the analysis of the standard parts,the failure causes are determined.The reliability of the optimization scheme is verified by Computer Aided Engineering analysis,bench test and road test.The results show that after optimization,the maximum stress of the part is reduced by more than 30%,the fatigue life has been greatly improved.Due to the weak mechanical properties of aluminum alloy products relative to iron castings,stress concentration has a greater impact on the fatigue life of parts.When designing aluminum casting parts,the smooth transition of part surface structure shall be ensured.