基于仿真优化的一体化连接支架的设计开发

Design and Development of an Integrated Connection Bracket Based on Simulation Optimization

针对商用车行业应用的钣金冲焊连接支架存在的可制造性不良问题,运用结构应力有限元和铸造工艺仿真相结合方法进行全新结构设计开发。经结构、工艺设计与选材优化,新开发的球墨铸铁一体化铸造连接支架经X射线探伤检测,整体未见缩孔、缩松类缺陷,铸造质量良好,较现钣金冲焊结构实现减重23%、降成本25%的精益目标,且具有更好的承载可靠性。整车可靠性验证表明,新开发结构符合整车可靠性,达成车辆品质要求。

Addressing the poor manufacturability issues of brackets with sheet metal welding connection in the commercial vehicle industry,a novel structural design and development approach was employed using a combination of structural stress finite element analysis and casting process simulation.Through structural and process design,as well as material selection and optimization,the newly developed nodular iron integrated connection bracket casting exhibited no shrinkage or looseness defects after X-ray inspection.The casting quality was excellent,achieving a lean target of 23%weight reduction and 25%cost reduction compared to the current sheet metal welding structure.It also had improved load-bearing reliability.Vehicle reliability verifi-cation indicated that the newly developed structure met the overall vehicle reliability requirements,fulfilling the vehicle quality standards.