Research on the Lightweight Design of Body-Side Structure Based on Crashworthiness Requirements

Crashworthiness is the most significant variable during lightweight design of vehicle structures.However,crashworthiness studies using the single substructure-based method are limited due to the negligence of interactions among substructures.Thus,a whole structure-based study was conducted for the lightweight design of a body-side structure.In this study,a full finite element model was firstly created and then modified into a simplified model for structural improvements,where the major load-carrying subassemblies were improved from the perspectives of crashworthiness and manufacturing costs.Finally,sensitivity analyses were conducted to further optimize the strength distribution,based on which an adaptive response surface method was employed for thickness optimization of the structure.It is found that through the structural improvements and optimizations,the weight of the structure was significantly reduced even when its crashworthiness was improved.This indicates that the whole structure-based method is effective for lightweight design of vehicle structures.     

驱动桥准双曲面齿轮传动误差有限元分析与试验

基于驱动桥总成的有限元模型,仿真分析准双曲面齿轮的传动误差,并搭建驱动桥总成传动误差的试验平台,测得不同工况下准双曲面齿轮的传动误差。仿真结果表明,随着转矩的增加,准双曲面齿轮的传动误差的曲线整体向下平移,传动误差的幅值先减小后增加:小负载转矩时,随着转矩的增加,齿轮的变形补偿作用使传动误差的幅值减小;而当转矩继续增加,传动误差的曲线超出设计的传动误差曲线的下端时,齿轮出现边缘接触,使传动误差的幅值反而变大,试验的结果显示同样的规律。     

基于焊点与相邻单元一体化应变能的灵敏度评价方法研究

焊点对于结构的动刚度有很大的影响,在以结构动刚度作为目标的焊点优化中,焊点灵敏度的评价至关重要。鉴于目前焊点灵敏度的评价方法在某些情况下可能导致错误结果,本文中提出一种基于焊点与相邻单元一体化应变能的灵敏度评价方法,并与传统方法进行了对比验证。结果表明,本文中提出的方法能更准确地反映焊点对于结构动刚度的影响程度。     

兼顾鲁棒性的多目标焊点自适应优化方法

电阻点焊是白车身制造过程中主要的装配工艺手段,其数量和布置会对白车身动刚度和静刚度产生很大的影响,但这两种影响并不总是一致的。因此,在以同时提升动/静刚度为目标的焊点优化中,需要一种能够兼顾动刚度和静刚度的指标,同时还要确保生产中的工业鲁棒性,使焊点设计方案实施效果不会轻易受到焊点制造缺陷的影响。本文中提出了一种以焊点及相邻单元应变能为基础,兼顾动刚度性能和静刚度性能的焊点优化决策指标,并利用该指标,构建了高效的鲁棒性分析方案,从而形成了一种多目标的焊点自适应优化方法,能实现同时考虑多种性能指标和鲁棒性的焊点优化过程。该方法被应用于某款轻型客车白车身焊点的性能优化和鲁棒性分析,并通过试验验证了其有效性。     

基于仿生的A柱-后视镜区域气动降噪研究

在某SUV车型的A柱-后视镜区域建立了6种仿生模型,稳态计算采用SST k-ω湍流模型,瞬态计算采用大涡模拟(LES),探讨了流场和声场的气动特性。仿真与风洞实验结果对比表明,仿真的监测点压力系数与实验数据基本吻合,1/3倍频程声压级曲线也比较一致。仿真结果表明,6种仿生模型都起到了降低噪声的作用,尤其在人耳敏感的中高频域降噪效果更为明显。其中,仿生模型1(A柱凸起结构)与原模型相比,降低了涡流强度,对流线具有梳理作用。总声压级的分析表明,仿生凸起模型局部降噪效果明显,仿生凹坑模型降噪效果均匀。