基于拓扑优化的客车骨架轻量化设计

Lightweight Design of Bus Skeleton Based on Topology Optimization

以某混合动力客车车身骨架为研究对象,利用HyperWorks对车身骨架进行静态分析和模态分析。以客车车身骨架总柔度最小为优化目标,设计区域的体积分数为约束条件,设计区域各单元的相对密度为设计变量,对客车的车底骨架、车顶骨架及左右侧围骨架进行拓扑优化设计,提取出客车车身的拓扑结构。在4种典型工况下,对优化前和优化后的车身骨架的强度、刚度进行了分析。结合正面碰撞的模拟分析,验证了客车骨架在碰撞条件下的安全性能。结果表明,在满足车身性能的前提下,优化后的客车骨架减重5.25%,满足轻量化要求。

Taking the body frame of a hybrid electric bus as the research object,the static analysis and modal analysis of the body frame were carried out by using HyperWorks.The minimum total flexibility of the bus body skeleton was taken as the optimization objective.The volume fraction of the design area was taken as the constraint.The relative density of each unit in the design area was taken as the design variable.The topology optimization design of the underbody skeleton,the roof skeleton and the left and right side surround skeleton of the bus were carried out to extract the topology of the bus body.The strength and stiffness of the pre-optimized and optimized body skeleton were analyzed under four typical operating conditions.Combined with the simulation analysis of frontal collision,the safety perfor⁃mance of the bus skeleton under the collision conditions was verified.The results show that the opti⁃mized bus skeleton reduces the weight by 5.25%to meet the lightweight requirement under the premise of meeting the body performance.