Holistic Topology and Parameter Lightweight Design of Composite Tailgate Structures

doi:10.3969/j.issn.1004-132X.2024.10.012

Abstract

Abstract: A holistic topology and parameter lightweight design method for the tailgate of a new energy vehicle was proposed by combining injection-molded long glass fiber-reinforced(LGF) polymer composite. The co-simulation models and conventional simulation models were established for the performance simulation and optimization design of the tailgates respectively, to improve simulation accuracy and optimization efficiency. Firstly, the composite tailgate structures were optimized and redesigned by three steps structural conceptal design based on conventional simulation models. Secondly, co-simulation models were established for subsequent multi-objective optimization and verified by sample production and performance tests. Finally, the elitist non-dominated sorting genetic algorithms (NSGA-Ⅱ) were used to optimize the rib thicknesses, key position thicknesses, and cross-sectional dimensions of the tailgates in detail. The mass of optimized composite tailgates is reduced by 27.2% compared to original steel tailgates, and the torsional stiffness, transverse stiffness, bending stiffness, and free mode of the tailgates meet the application requirements.

Key words: long glass fiber-reinforced(LGF) polymer composite, tailgate, co-simulation, conceptal design, parameter optimization

摘要： 以某新能源车型的尾门为研究对象，结合注塑长玻纤增强复合材料，提出了一种结构拓扑参数一体化轻量化设计方法，并为尾门性能仿真和优化设计分别建立了联合仿真和常规仿真模型，提高了仿真精度和优化效率。首先，基于常规仿真模型通过三步式结构概念设计优化并重新设计了复合材料尾门结构。然后，建立了用于后续多目标优化的联合仿真模型，并通过样件试制和性能试验进行了验证。最后，利用带精英策略的非支配排序遗传算法（NSGA-Ⅱ）对尾门的筋条厚度、关键位置厚度、截面尺寸进行了详细优化。优化后的复合材料尾门质量比原钢制尾门减小了27.2%，同时尾门扭转刚度、横向刚度、弯曲刚度及自由模态满足应用要求。

关键词: 长玻纤增强复合材料, 尾门, 联合仿真, 概念设计, 参数优化

CLC Number:

U463.83

CHENG Aiguo1, WANG Chao1, LU Rijin2, HE Zhicheng1, YU Wanyuan3. Holistic Topology and Parameter Lightweight Design of Composite Tailgate Structures[J]. China Mechanical Engineering, 2024, 35(10): 1824-1833.

成艾国1, 王超1, 陆日进2, 何智成1, 于万元3. 复合材料尾门结构的拓扑参数一体化轻量化设计[J]. 中国机械工程, 2024, 35(10): 1824-1833.

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