铝型材截面设计系统开发及其在轻卡护栏轻量化中的应用

Development of Aluminum Section Design System and its Application in Lightweight Design of Light Truck Guardrail

各种截面铝型材具有模具费用低、成型效率高、比强度高和通用性强等优点,在各类具有轻量化要求的骨架结构中应用越来越广。利用PYTHON语言开发了铝合金型材截面参数化模型和专用图形用户交换界面(GUI),以插件形式与现有有限元软件进行数据传递。对快速建模和计算过程进行批处理,将获得的大量数据进行拟合,可获得复杂结构的Kriging代理模型;结合粒子群算法可获得最优解。利用该软件,对某轻型轻卡侧面碰撞防护栏结构进行“以铝代钢”的轻量化设计。以刚度和强度为约束,以质量最轻为目标,通过优化截面和连接参数,根据拉挤工艺可行性,在保证使用安全的前提下,减重56.94%。

Aluminum alloy profiles of various cross-section have been applied more and more in framework structures with lightweight requirements on account of the low tooling cost,high extrusion efficiency,high specific strength and strong versatility. In this paper,PYTHON program was used to develop a parametric model of various aluminum alloy section and a dedicated graphical user exchange interface(GUI)to transfer data with existing finite element software in the form of a plug-in. The rapid modeling and calculation process were processed by batch,and the Kriging surrogate model of complex structures could be established based on large amount of simulation data. The optimum design could be obtained when combined with particle swarm algorithm.As an application example of substituting aluminum instead for steel,the side guardrail structure of a light truck was designed by this software system. Taking the lightest weight as the objective,and the stiffness and strength as the constraints,the cross-section and connection parameters were optimized. On the premise that the extrusion formability and safety,the weight of newly designed side guardrail with aluminum frames have reduced 56.94%.