铝制发动机盖减小刚度冗余的减重方法研究

Study on the uniform stiffness lightweighting method of aluminum engine hood

以某国产车的钢制发动机盖内板为研究对象,通过对钢制发动机盖进行刚度分析,发现存在某些刚度过高、刚度分布不均匀的现象,说明原发动机盖结构设计不合理。对此,本研究首先采用铝合金替换钢,实现发动机盖减重,然后采用拓扑优化技术优化结构传力路径,重新进行结构设计,实现发动机盖刚度冗余分布均匀;最后运用尺寸优化方法对发动机盖零部件的厚度进行合理匹配,保证发动机盖在满足性能指标的前提下实现最大程度的减重。钢制发动机盖经过铝合金材料替换、拓扑优化及尺寸优化后,在满足刚度指标的前提下,实现发动机盖减重6.22 kg,减重率高达37.2%,取得了良好的轻量化效果,对后续发动机盖的轻量化设计具有一定的借鉴意义。

Taking the steel engine hood inner panel of a domestic vehicle as the research object,excessive performance and uneven performance distribution were found after perform-ance analysis of the steel engine hood,indicating unreasonable design of the original engine hood structure.The following procedures were adopted to address this issue.First,alumi-num alloy materials were used for material replacement to achieve weight reduction.Further-more,topology optimization technology was used to optimize the structural force transmission path and the structure was redesigned to achieve uniform distribution of engine hood perform-ance.Finally,the size optimization method was used to reasonably match the thicknesses of the engine hood components,ultimately achieving maximum weight reduction while ensuring that the engine hood meets performance indicators.After replacing the steel engine hood with aluminum alloy materials,topology optimization,and size optimization,the engine hood achieved a weight reduction of 6.22 kg while meeting performance indicators,with a weight reduction rate of up to 37.2%,achieving good lightweighting effect.This has certain reference significance for the subsequent lightweighting design of the engine hood.