摘要
针对某车型一体压铸铝合金超大尺寸后段车身耐久开发问题,测试了压铸车身用铸态铝合金应变-寿命(E-N)数据,并对疲劳试样实测数据拟合得到合金E-N曲线关键参数;搭建Trim Body有限元模型,基于模态瞬态法计算了压铸车身应力动态响应,对应力时程响应信号雨流统计,结合实测拟合的E-N曲线和Miner损伤累积原理,对比分析了车身初始设计和优化设计方案的疲劳损伤;最后将优化设计的一体压铸件装车进行整车四立柱强化耐久测试。研究结果表明:压铸铝合金E-N关系曲线可用Manson-Coffin-Basquin方程描述;与初始方案比,改进设计的一体压铸铝合金车身最大损伤由2.67降低至0.32,疲劳开裂风险消除,经四立柱强化耐久试验验证一体压铸铝车身未见开裂。研究成果可为一体压铸铝合金车身达成耐久属性开发目标提供参考依据。
For the durability development problem of an vehicle with super-size integral die casing aluminum alloy rear end body,the E-N data of the cast aluminum alloy for the die casting body is tested and the key parameters of die-casting alloy E-N curve are obtained by fitting the experimental measured data of fatigue samples.Finite element model of Trim body is built and the dynamic stress response of the die casting body is calculated based on the modal transient method.Rain flow statistics is carried out to the stress time history response signal.Combined with the measured material E-N curve and Miner’s damage accumulation principle.,the body fatigue damage of initial design and optimized design are analyzed and compared.Finally,the optimized integral die casting part is loaded into the vehicle for the four-column strengthening durability test.The investigation results show that the E-N relation curve of die casting aluminum alloy can be described by Manson-Coffin-Basquin equation.Compared with the original design,the maximum damage of the improved integrated die casting aluminum alloy body is reduced from 2.67 to 0.32,and the risk of fatigue cracking is eliminated.No cracks are found in the body after the reinforced fourcolumn endurance experiment verification.The research results can provide a reference for the development of integral die-cast aluminum alloy body to achieve the goal of vehicle durability properties.
作者
曾维和
苟黎刚
罗宇
张俊
廖慧红
Zeng Weihe;Gou Ligang;Luo Yu;Zhang Jun;Liao Huihong(Geely Automobile Research Institute Ningbo Co.,Ltd.,Ningbo315336)
出处
《汽车工程》
EI
CSCD
北大核心
2023年第7期1263-1275,共13页
Automotive Engineering
关键词
一体式压铸
铸铝车身
E-N
疲劳仿真
耐久验证
integral die casting
cast aluminum body
E-N,fatigue simulation
endurance verification
作者简介
通信作者:曾维和,工程师,E-mail:weihe.zeng@geely.com。
