一体压铸式副车架创新优化设计

Innovative and Optimized Design of Integrated Die-casting Subframe

汽车零部件的轻量化设计可以有效助推整车轻量化,提升产品品质,助力企业实现降本增效。以某款新能源汽车的副车架为研究对象,采用结构轻量化、工艺轻量化两大核心轻量化方法进行副车架结构创新优化设计。采用一体压铸工艺代替原有的拼焊工艺,作为结构优化的方向,对拼焊式副车架进行全面分析,提取刚度、强度、模态和动刚度等性能作为结构优化的优化目标和约束。使用MMO多模型优化技术将柔度目标和质量目标进行合成拓扑优化,对优化后的结构进行载荷传递路径的解读和结构重塑。进一步进行参数优化,确定结构的最佳厚度。优化后副车架再次进行性能和工艺分析,经分析新设计副车架一阶模态提升45.3HZ,提升了16.5%;最大应力(工况4)降低153.2MPa,强度提升48.1%;各接附点刚度和动刚度性能也均有不同程度的提升;新结构重量降低2kg,降低了15.6%,单件加工成本降低41.62元,降低了8.6%。新副车架实现性能提升、降重降本的设计目标。

The lightweight design of automotive components can effectively promote the lightweight of the entire vehicle,improve product quality,and assist enterprises in achieving cost reduction and efficiency increase.Taking a new energy vehicle subframe as the research object,two core lightweight methods,structural lightweight and process lightweight,were adopted for innovative and optimized design of the subframe structure.Adopting the integrated die-casting process instead of the original welding process as the direction of structural optimization,a comprehensive analysis is conducted on the splice welded subframe,and the performance of stiffness,strength,modal and dynamic stiffness are extracted as the optimization objectives and constraints of structural optimization.Using MMO multi model optimization technology to compliance and mass objectives for topology optimization,interpreting the load transfer path and reshaping the optimized structure.Further parameter optimization is carried out to determine the optimal thickness of the structure.The optimized subframe underwent performance and process analysis again.After analysis,the first-order modal of the newly designed subframe increased by 45.3HZ,an increase of 16.5%;The maximum stress(working condition 4)decreased by 153.9 MPa,and the strength increased by 48.2%;The stiffness and dynamic stiffness performance of each attachment point also have varying degrees of improvement;The new structure has a weight reduction of 2KG,a reduction of 15.6%,and a single piece processing cost reduction of 41.62 yuan,a reduction of 8.6%.The new subframe has achieved the design goals of improving performance and reducing weight and cost.