基于拓扑优化的汽车电子加速踏板轻量化设计与增材制造

Lightweight Design and Additive Manufacturing of Automotive ElectronicAccelerator Pedal Based on Topology Optimization

零件的轻量化是新能源汽车提高其能量利用率的重要途径之一。基于拓扑优化方法和FDM增材制造技术,对新能源汽车电子加速踏板进行了拓扑优化设计:采用双向拔模的形状控制方法,以最小化重量为目标对连杆部进行了拓扑优化,使其减重164.75g;采用辐射状形状控制方法,以最小重量为目标对踩踏部进行了拓扑优化,使其减重42.88g;电子加速踏板经过拓扑优化后的总重量为150.57g,相比于初始状态的358.21g减少了207.64g,减重率为57.97%,最大等效应力17.47Mpa,最小安全系数为2.6,最大变形量为6.57e-1mm;利用增材制造的方式对优化结果进行了验证;为其他类似零部件的优化设计提供了参考。

Lightweight parts are one of the important ways for new energy vehicles to improve their energy utilization efficiency.This article is based on the topology optimization method and FDM additive manufacturing technology to perform topology optimization design on the electronic accelerator pedal of new energy vehicles:the shape control method of bidirectional draft is adopted to optimize the topology of the connecting rod with the goal of minimizing weight,resulting in a weight reduction of 164.75g;the radial shape control method is used to optimize the topology of the treading part with the goal of minimizing weight,resulting in a weight reduction of 42.88g;after topology optimization,the total weight of the electronic accelerator pedal is 150.57g,which is 207.64g less than the initial state of 358.21g.The weight reduction rate is 57.97%,the maximum equivalent stress is 17.47Mpa,the minimum safety factor is 2.6,and the maximum deformation is 6.57e-1mm;And the optimization results are validated using additive manufacturing,providing a reference for the optimization design of other similar components.