汽车发动机连接支架拓扑优化及增材制造研究

doi:10.3969/j.issn.1004-132X.2023.18.011

摘要/Abstract

摘要： 开展汽车发动机连接支架拓扑优化及增材制造研究，利用ANSYS Workbench软件中的Topology Optimization模块对汽车发动机空调压缩机连接支架进行拓扑优化，并开展增材制造工艺研究，完成拓扑优化件打印。打印件与铸件相比质量减小约43.8%，一阶共振频率提高约23%（提高到255 Hz），且优化后的支架结构力学性能显著优于原铸件的力学性能；同时进行增材制造铝合金件热处理方法研究，获得了较优的热处理方法。实现了汽车发动机关键零部件的拓扑优化增材制造一体化技术开发。

关键词: 汽车发动机, 轻量化, 拓扑优化, 增材制造

Abstract: The topology optimization and additive manufacturing of automotive engine connecting brackets were studied. Topology optimization module of ANSYS Workbench was used to optimize the connecting brackets of automotive engine air-conditioning compressors, the mass was reduced by about 43.8% and the first-order resonance frequency was increased by about 23%(increase to 255 Hz), and the mechanics properties of the optimized structures were significantly better than those of the original castings. The heat treatment system of aluminum alloy parts made by additive manufacturing was studied, and a better heat treatment system was obtained. The integrated technology of topology optimization and additive manufacturing of the key components of automobile engine was developed.

Key words: automobile engine, light weight, topology optimization, additive manufacturing

中图分类号:

刘英杰, 胡强, 赵新明, 张少明, 黄帅, 王永慧. 汽车发动机连接支架拓扑优化及增材制造研究[J]. 中国机械工程, 2023, 34(18): 2238-2267.

LIU Yingjie, HU Qiang, ZHAO Xinming, ZHANG Shaoming, HUANG Shuai, WANG Yonghui. Research on Topology Optimization and Additive Manufacturing of Automotive Engine Connection Brackets[J]. China Mechanical Engineering, 2023, 34(18): 2238-2267.

参考文献

［1］李光霁，刘新玲．汽车轻量化技术的研究现状综述［J］．材料科学与工艺，2020，28(5) :47-61．
LI Guangji , LIU Xinling．Literature Review on Research and Development of Automotive Lightweight Technology［J］．Materials Science and Technology, 2020, 28(5) :47-61.
［2］洪腾蛟，董福龙，丁凤娟，等. 铝合金在汽车轻量化领域的应用研究［J］. 热加工工艺, 2020, 49(4):1-6.
HONG Tengjiao, DONG Fulong, DING Fengjuan, et al. Application of Aluminum Alloy in Automotive Lightweight［J］. Hot Working Technology，2020, 49(4):1-6.
［3］华林，魏鹏飞，胡志力. 高强轻质材料绿色智能成形技术与应用［J］.中国机械工程, 2020, 31(22):2753-2762
HUA Lin, WEI Pengfei, HU Zhili. Green and Intelligent Forming Technology and Its Applications for High Strength Lightweight Materials［J］. China Mechanical Engineering , 2020,31(22):2753-2762.
［4］LIU Shutian, LI Quhao, LIU Junhuan, et al. A Realization Method for Transforming a Topology Optimization Design into Additive Manufacturing Structures［J］. Engineering,2018,4(2):277-285.
［5］王仁，杨伟群. 选择性激光熔化技术及面向航空组件的拓扑优化研究［J］. 现代制造工程, 2018 (12):24-30.
WANG Ren, YANG Weiqun. SLM Technology and Topology Optimization for Lighter Aerospace Components［J］. Modern Manufacturing Engineering, 2018 (12):24-30.
［6］赵剑峰，马智勇，谢德巧，等. 金属增材制造技术［J］. 南京航空航天大学学报, 2014,46(5):675-683.
ZHAO Jianfeng, MA Zhiyong, XIE Deqiao, et al. Metal Additive Manufacturing Technique［J］. Journal of Nanjing University of Aeronautics & Astronautics, 2014,46(5):675-683.
［7］杨平华，高祥熙，梁菁，等. 金属增材制造技术发展动向及无损检测研究进展［J］. 材料工程,2017,45(9):13-21.
YANG Pinghua, GAO Xiangxi, LIANG Jing, et al. Development Tread and NDT Progress of Metal Additive Manufacture Technique［J］. Journal of Materials Engineering,2017,45(9):13-21.
［8］乐国敏，李强，董鲜峰，等. 适用于金属增材制造的球形粉体制备技术［J］. 稀有金属材料与工程， 2017, 46(4):1162-1168.
LE Guomin, LI Qiang, DONG Xianfeng, et al. Fabrication Techniques of Spherical-shaped Metal Powders Suitable for Additive Manufacturing［J］. Rare Metal Materials and Engineering, 2017, 46(4):1162-1168.
［9］姜海燕，林卫凯，吴世彪，等. 激光选区熔化技术的应用现状及发展趋势［J］. 机械工程与自动化, 2019 (5):223-226.
JIANG Haiyan, LIN Weikai, WU Shibiao, et al. Application Status and Development Trend of Laser Selective Melting Technology［J］. Mechanical Engineering & Automation, 2019(5):223-226.
［10］杨强，鲁中良，黄福享，等. 激光增材制造技术的研究现状及发展趋势［J］. 航空制造技术, 2016 (12):26-31.
YANG Qiang, LU Zhongliang, HUANG Fu-xiang, et al. Research on Status and Development Trend of Laser Additive Manufacturing［J］. Aeronautical Manufacturing Technology, 2016 (12):26-31.
［11］李昂，刘雪峰，俞波，等. 金属增材制造技术的关键因素及发展方向［J］. 工程科学学报, 2019, 41(2):159-173.
LI Ang, LIU Xuefeng, YU Bo, et al. Key Factors and Developmental Directions with Regard to Metal Additive Manufacturing［J］. Chinese Journal of Engineering, 2019, 41(2):159-173.
［12］郭志飞，张虎. 增材制造技术的研究现状及其发展趋势［J］. 机床与液压, 2015, 43(5):148-151.
GUO Zhifei, ZHANG Hu. Research Status and Development Trend of Additive Manufacturing Technology［J］. Machine Tool & Hydraulics, 2015, 43(5):148-151.
［13］刘书田，李取浩，陈文炯，等. 拓扑优化与增材制造结合:一种设计与制造一体化方法［J］. 航空制造技术, 2017 (10):26-31.
LIU Shutian, LI Quhao, CHEN Wenjiong, et al. Combination of Topology Optimization and Additive Manufacturing:an Integration Method of Structural Design and Manufacturing［J］. Aeronautical Manufacturing Technology, 2017(10):26-31.
［14］朱继宏，周涵，王创，等. 面向增材制造的拓扑优化技术发展现状与未来［J］. 航空制造技术, 2020, 63(10):25-38.
ZHU Jihong, ZHOU Han, WANG Chuang, et al. Status and Future of Topology Optimization for Additive Manufacturing［J］. Aeronautical Manufacturing Technology, 2020, 63(10):25-38.
［15］王玉，李帅帅，于颖. 面向增材制造的零件结构及工艺设计［J］. 同济大学学报（自然科学版）,2020,48(6):869-879.
WANG Yu, LI Shuaishuai, YU Ying. Structure Design and Process Planning for Additive Manufacturing［J］. Journal of Tongji University(Natural Science), 2020,48(6):869-879.
［16］常天行，刘彬，方学伟，等. 铝合金增材制造的发展现状与展望［J］. 宇航材料工艺,2022,52(2):76-84.
CHANG Tianxing, LIU Bin, FANG Xuewei， et al. Development Status and Prospect of Aluminum Alloy Additive Manufacturing［J］. Aerospace Materials & Technology, 2022,52(2):76-84.
［17］王震，巩维艳，祁俊峰，等. 基于增材制造的设计理论和方法研究现状［J］. 新技术新工艺， 2017(10):31-35.
WANG Zhen, GONG Weiyan, QI Junfeng, et al. Present Research on Design Philosophy and Technique about Additive Manufacturing［J］. New Technology & New Process, 2017(10):31-35.
［18］HO J Y, LEONG K C, WONG T N. Additively-manufactured Metallic Porous Lattice Heat Exchangers for Air-side Heat Transfer Enhancement［J］. International Journal of Heat and Mass Transfer, 2020, 150:119262.
［19］石立. 基于隐式曲面建模的异型三维点阵结构造型算法研究［D］. 南京:南京理工大学,2017.
SHI Li. Research on Modeling Algorithm of Irregular 3D Lattice Structure Based on Implicit Surface Modeling［D］. Nanjing:Nanjing University of Science and Technology, 2017.
［20］郑胤峥. 极小曲面点阵结构力、热性能及优化设计研究［D］. 南京:南京理工大学,2018.
ZHENG Yinzheng. Study on Structural Force, Thermal Performance and Optimal Design of Curved Lattice［D］. Nanjing:Nanjing University of Science and Technology, 2018.
［21］崔厚学，高方勇，魏青松. 3D打印在汽车制造中的应用展望［J］. 汽车工艺师，2016(9):36-41.
CUI Houxue, GAO Fangyong, WEI Qingsong. Application Prospect of 3D Printing in Automobile Manufacturing［J］. Auto Manufacturing Engineer, 2016(9):36-41.
［22］纵荣荣，李海鹏，葛广跃，等. 3D打印技术在汽车行业的应用［J］. 汽车实用技术，2022,47(11):195-199.
ZONG Rongrong, LI Haipeng, GE Guangyue, et al. Application of 3D Printing Technology in Automobile Industry［J］. Automobile Applieo Technology, 2022, 47(11):195-199.
［23］童身亮. 发动机轻量化途径及工艺创新探究［J］. 内燃机与配件,2021(5):33-34.
TONG Shenliang. Research on the Way and Technology Innovation of Light Weight Engine［J］. Internal Combustion Engine & Parts, 2021(5):33-34.
［24］ESCHENAUER H A, OLHOFF N. Topology Optimization of Continuum Structures:a Review［J］. Applied Mechanics Reviews:an Assessment of the World Literature in Engineering Sciences, 2001, 54(4):331-390.
［25］ZHOU M , ROZVANY G I N. On the Validity of ESO Type Methods in Topology Optimization［J］. Structural and Multidisciplinary Optimization, 2014, 21(1):80-83.
［26］张龙，李昂，赵云鹏，等. 一种全封闭蒙皮点阵支撑结构的优化设计与试验验证［J］. 机械工程学报， 2021, 57 (22):35-42.
ZHANG Long, LI Ang, ZHAO Yunpeng, et al. Optimal Design and Experimental Verification of an Enclosed Skin Lattice Support Structure［J］. Journal of Mechanical Engineering, 2021,57(22):35-42.
［27］SIMCHI A. Direct Laser Sintering of Metal Powders:Mechanism, Kinetics and Microstructural Features［J］. Materials Science & Engineering, A. Structural Materials:Properties, Misrostructure and Processing, 2006, A428(1/2):148-158.
［28］倪晓晴，孔德成，温莹，等. 3D打印金属材料中孔隙率的影响因素和改善方法［J］. 粉末冶金技术,2019,37(3):163-169.
NI Xiaoqing, KONG Decheng, WEN Ying, et al. Influence Factors and Improvement Methods on the Porosity of 3D Printing Metal Materials［J］. Powder Metallurgy Technology, 2019,37(3):163-169.
［29］王迪，欧远辉，窦文豪，等. 粉末床激光熔融过程中飞溅行为的研究进展［J］. 中国激光,2020,47(9):1-15.
WANG Di, OU Yuanhui, DOU Wenhao, et al. Research Progress on Spatter Behavior in Laser Powder Bed Fusion［J］. Chinese Journal of Lasers,2020,47(9):1-15.
［30］王学才，卢云，何仲云，等. 选择性激光熔化AlSi10Mg合金组织形貌及其拉伸性能［J］. 安徽工业大学学报（自然科学版）,2017,34(3):234-240.
WANG Xuecai, LU Yun, HE Zhongyun, et al. Microstructure and Tensile Properties of Selective Laser Melting AlSi10Mg Alloy［J］. Journal of Anhui University of Technology(Natural Science), 2017,34(3):234-240.
［31］闫泰起，唐鹏钧，陈冰清，等. 退火温度对激光选区熔化AlSi10Mg合金微观组织及拉伸性能的影响［J］. 机械工程学报,2020,56(8):37-45.
YAN Taiqi, TANG Pengjun, CHEN Bingqing, et al. Effect of Annealing Temperature on Microstructure and Tensile Properties of AlSi10Mg Alloy Fabricated by Selective Laser Melting［J］. Journal of Mechanical Engineering, 2020,56(8):37-45.

[1]	柯庆镝, 罗俊友, 蒋守志, 黄海鸿, . 基于涂层材料分布状态的超声应力反演模型构建[J]. 中国机械工程, 2023, 34(18): 2230-2237.
[2]	董小虎, 王士涛, 周德淳. 光伏跟踪支架檩条结构高刚性轻量化设计[J]. 中国机械工程, 2023, 34(10): 1207-1213.
[3]	王磊, 邬宇梁, 赵纪元, , 卢秉恒, . 增材制件内流道精整加工技术研究进展[J]. 中国机械工程, 2023, 34(07): 757-769.
[4]	方学伟, 蒋笑, 王喆, 武晓康, 黄科. ER120S-G高强钢电弧增材制造的工艺优化[J]. 中国机械工程, 2023, 34(02): 218-225.
[5]	韩光超, , 杨家凯, 叶泽玖, 徐林红, 张海鸥, 杨海涛. 电弧微铸锻增材制造AlMgSc合金纵扭复合超声振动干铣削加工特性研究[J]. 中国机械工程, 2022, 33(24): 2971-2979,2989.
[6]	文桂林, 陈高锡, 王洪鑫 , 薛亮, 魏鹏, 刘杰, . 含自重载荷的功能梯度材料结构时域动力学拓扑优化设计[J]. 中国机械工程, 2022, 33(23): 2774-2782.
[7]	贺红林, 赵伟鹏, 余志豪, 龙玉繁, 鄢殷期, 李冀. 约束阻尼板双线性材料插值法拓扑动力学优化[J]. 中国机械工程, 2022, 33(23): 2783-2789，2878.
[8]	丁延冬, 罗年猛, 杨奥迪, 王书亭, 朱浩然, 谢贤达. Bézier单元刚度映射下的高效多重网格等几何拓扑优化方法[J]. 中国机械工程, 2022, 33(23): 2801-2810.
[9]	杨雨豪, 郑伟, 王英俊, . 一种自由度缩减和收敛加速的高效等几何拓扑优化方法[J]. 中国机械工程, 2022, 33(23): 2811-2821.
[10]	孟亮, 仲明哲, 李文彪, 夏凉, 高彤, 朱继宏, 张卫红, . 面向增材制造的航空发动机外部系统支架拓扑优化设计[J]. 中国机械工程, 2022, 33(23): 2822-2832.
[11]	邹无有, 杜纯, 艾建平, 单斌. 面向催化剂载体应用的TiO2多孔陶瓷结构优化设计[J]. 中国机械工程, 2022, 33(23): 2833-2843.
[12]	焦晨, 晁龙, 朱磊, 沈理达, 梁绘昕, 戴宁, 王长江, 孙骏. 面向骨科植入物的仿生多孔结构设计与制造方法[J]. 中国机械工程, 2022, 33(23): 2844-2850.
[13]	贾连辉, 李晓科, 袁文征, 何文斌, 廖兆锦. 基于拓扑优化和Kriging模型的前中盾结构轻量化设计[J]. 中国机械工程, 2022, 33(23): 2888-2897.
[14]	曹腾, 李晓牛, 王柏权, 温智益, 吴大伟. 单相压电电机驱动的高精度孔径光阑设计[J]. 中国机械工程, 2022, 33(20): 2414-2419.
[15]	何智成, 杨丁丁, 姜潮, 伍毅, 江和昕. 基于增材制造各向异性的强度约束拓扑优化[J]. 中国机械工程, 2022, 33(19): 2372-2380，2393.