某车型内高压成形结构后副车架产品与工艺开发

Product and process development on hydroforming structure rear sub-frame for a certain vehicle

为实现乘用车底盘副车架轻量化和低成本设计,基于某车型冲焊结构后副车架,全新开发内高压成形结构后副车架。利用产品有限元仿真技术验证了内高压成形结构后副车架的耐久性和强度满足要求。针对内高压成形纵梁,提出一种一模S型双件出件的低成本化工艺设计方式,实现一模双出,提升了制造效率,实现材料利用率从91.0%提升至93.5%。利用工艺成形有限元仿真技术验证了内高压成形纵梁一模S型双件成形件具有良好的可制造性,其最大减薄率为18.0%,满足要求,并制定了全工序工艺方案。通过产品和工艺有限元的仿真技术驱动了结构轻量化、低成本化和可制造性设计,利用成本模型详细评估了两种结构的成本差异。完成了总成样件试制和总成台架试验,验证了内高压成形结构后副车架产品和工艺开发的可行性,实现了减重15.1%、制造成本降低15.8%。

In order to realize the lightweight and low-cost design of passenger vehicle chassis sub-frame,based on the punching and welding structure of rear sub-frame for a certain vehicle,the hydroforming structure rear sub-frame was newly developed,and the finite element simulation technology of product was used to verify that the durability and strength of the hydroforming structure rear sub-frame meet the requirements.Then,for the hydroforming longitudinal beam,a low-cost process design method which realized one die producing two S-typed pieces was proposed to improve the manufacturing efficiency,and the material utilization rate was increased from 91.0%to 93.5%.Furthermore,the finite element simulation technology of process forming was used to verify the good manufacturability of the one die producing two S-typed pieces for hydroforming longitudinal beam,the maximum thinning rate was 18.0%to meet the requirements,and the whole process scheme was formulated.Finally,the design of structure lightweight,low-cost and manufacturability were driven by the finite element simulation technology of product and process,and the cost difference between the two structures was evaluated in detail by the cost model.The results of the trial production of assembly sample and the assembly bench test show that the feasibility of the product and process development for hydroforming structure rear sub-frame is verified,the weight reduction is 15.1%,and the manufacturing cost.is reduced by15.8%.