基于Optistruct的某皮卡汽车后桥壳轻量化优化研究

Research on the Lightweight Optimization of the Rear Axle Housing of a Pickup Truck Based on Optistruct

【目的】为研究某新款皮卡汽车后桥壳的静态特性及轻量化优化问题,【方法】采用有限元平台仿真与台架试验结合的研究方法。首先,在Hypermesh软件建立具有高计算精度的有限元模型;其次,使用ABAQUS仿真平台分析了桥壳在满载工况下的应力及位移,确定了危险截面位置;随后,通过Optistruct优化模块对桥壳和钢板板簧座等零部件进行了尺寸优化;最后,通过垂直弯曲静刚强度台架试验验证了轻量化优化的可靠性。【结果】有限元分析结果表明,桥壳的危险截面位于钢板板簧座与桥壳连接处,最大应力和变形量分别为307.20 MPa和1.440 mm。Optistruct尺寸优化后的桥壳重量由59.07 kg降低至52.55 kg,减重率11.04%。应力上升至310.10 MPa,但仍小于桥壳材料45钢的屈服强度355.00 MPa,变形量小于标准1.400 mm。台架试验结果表明,桥壳通过垂直弯曲静刚强度试验,符合汽车驱动桥台架试验标准。【结论】所建立的有限元模型具有较高的准确性,仿真结果与台架试验结果高度接近。经Optistruct优化后的桥壳具有良好的力学行为表现,该模块在桥壳轻量化优化方面具有较高的可靠性。

【Objective】In order to investigate the static characteristics and lightweight optimization of the rear axle housing of a new pickup truck vehicle,【Method】a research method combining finite element platform sim-ulation and bench testing was adopted.Firstly,a finite element model with high computational accuracy was es-tablished in Hypermesh software.Secondly,the stress and displacement of the axle shell under full load condi-tion were analyzed using ABAQUS simulation platform,and the location of the dangerous cross-section was de-termined.Subsequently,the dimensional optimization of the axle shell and the steel plate spring seat and other components was carried out through Optistruct optimization module,and then the reliability of the lightweight optimization was verified through vertical bending static stiffness bench test.Finally,the reliability of light-weight optimization was verified by vertical bending static stiffness bench test.【Result】Finite element analysis results show that the dangerous cross-section of the axle housing is located in the housing steel plate spring seat and housing connection with the maximum stress and deformation of 307.20 MPa and 1.440 mm.Size optimiza-tion of the axle housing weight decreases from 59.07 kg to 52.55 kg and the weight reduction rate is 11.04%.The stress rises to 310.10 MPa,but it is still less than the yield strength of 45 steel of the axle housing material,which is 355.00 MPa,and the deformation is less than the standard 1.400 mm.The results of the bench test show that the axle housing passes the vertical bending static stiffness test,and conforms to the standard of the automo-bile drive axle bench test.【Conclusion】The established finite element model has high accuracy,and the simula-tion results are highly close to the results of the bench test.The axle housing optimized by Optistruct has good mechanical behavior performance,and the module has high reliability in axle housing lightweighting.