基于数值仿真的1500MPa级抗疲劳扭力梁管梁研制与性能评价

Development and performance evaluation on 1500 MPa anti-fatigue torsion tubular beam based on numerical simulation

为提升扭力梁管梁的抗疲劳性,针对某电动出租车1500 MPa级抗疲劳扭力梁管梁的关键技术进行了研究,在完成管梁结构设计后,采用产品数值仿真和成形数值仿真技术分别验证了产品性能和可制造性能,完成了样件试制且通过了总成产品的试验验证,最终设计了一种既能满足抗疲劳性,又能实现轻量化和低成本要求的管梁正向开发技术。结果显示:在正向设计管梁结构时,需先利用侧倾中心反推出管梁剪切中心,再计算出管梁剪切中心,确定管梁X向和Z向位置后再进行结构的详细设计;产品数值仿真技术确认了管梁扭转刚度为435.5 N·m·deg^(-1)、扭转耐久外应力为454 MPa,均满足产品性能要求;成形数值仿真技术显示管梁的最大减薄率为12.9%,满足可制造性要求;高频淬火后,管梁的抗拉强度从420~800 MPa提升至1300~1700 MPa;扭转耐久台架试验和道路试验表明,高频淬火后的管梁抗疲劳性约为非高频淬火管梁的4倍。

In order to improve the fatigue resistance of the torsion tubular beam,the key technology of the 1500 MPa anti-fatigue torsion tubular beam of an electric taxi was studied,and after completing the design of the tubular beam structure,the product performance and manufacturability were verified by using the product numerical simulation and forming numerical simulation technology.Then,the proto-type was completed and passed the test verification of the assembly product.Finally,a forward development technology for tubular beams that not only met the requirements of fatigue resistance,but also met the requirements of lightweight and low cost was designed.The re-sults show that when designing the tubular beam structure forward,the shear center of the tubular beam should be firstly deduced from the side tilt center,and then the shear center of the tubular beam is calculated to determine the X and Z positions of the tubular beam before proceeding to detailed structure design.Torsional rigidity of the tubular beam 435.5 N·m·deg^(-1) and torsional durability external stress 454 MPa are confirmed by the product numerical simulation technology,which meet the product requirements.Maximum thinning rate 12.9%of the tubular beam is showed by using the forming numerical simulation technology,which meets the requirements of manufactur-ability.After high-frequency quenching,the tensile strength of tubular beam is increased from 420-800 MPa to 1300-1700 MPa,and the torsional durability bench tests and road tests show that the fatigue resistance of the tubular beam after high-frequency quenching is about four times that of the non-high-frequency quenching tubular beam.