Lightweight Optimization Design of Commercial Vehicle Frames Combined by Steel and Aluminum Materials under Multiple Working Conditions

doi:10.3969/j.issn.1004-132X.2020.18.008

Abstract

Abstract: In order to find effective lightweight schemes for commercial vehicles, the frame of a heavy commercial vehicle was taken as the research object, the finite element model was established and the free modal analysis and the static analysis of four typical working conditions were carried out. The frame optimization model was established by using the multidisciplinary optimization software HyperStudy, and the dimensions and materials of the frame were optimized simultaneously under four typical working conditions. The results show that the designed frame combined by steel and aluminum materials may effectively reduce the mass by 5.6% under certain strength and modal performance conditions.

Key words: commercial vehicle frame, steel-aluminum combination, multiple working condition, lightweight

摘要： 为寻求有效的商用车轻量化方案，以某重型商用车车架为研究对象，建立有限元模型并进行自由模态分析和4种典型工况的静态分析，运用多学科优化软件HyperStudy建立车架优化模型，并对4种典型工况下的车架同时进行尺寸和材料的优化。研究结果表明，在保证可靠的强度和模态特性条件下，所设计的钢铝材料结合车架能够有效减小5.6%的质量。

关键词: 商用车车架, 钢铝材料结合, 多工况, 轻量化

CLC Number:

U463.1

ZHANG Kaicheng；LI Shunming；SUN Mingjie. Lightweight Optimization Design of Commercial Vehicle Frames Combined by Steel and Aluminum Materials under Multiple Working Conditions[J]. China Mechanical Engineering, DOI: 10.3969/j.issn.1004-132X.2020.18.008.

张凯成；李舜酩；孙明杰. 钢铝材料结合的商用车车架多工况轻量化优化设计[J]. 中国机械工程, DOI: 10.3969/j.issn.1004-132X.2020.18.008.

References

[1]应朝阳. 国家标准《汽车、挂车及汽车列车外廓尺寸、轴荷及质量限值》(GB1589—2016)制修订情况介绍[J]. 汽车与安全, 2016(8)：90-94.
YING Zhaoyang. The Introduction to National Standard “Limits of Dimensions, Axle Load and Masses for Motor Vehicles, Trailers and Combination Vehicles”Revised Edition(GB1589—2016)[J]. Auto&Safety, 2016(8)：90-94.
[2]王大伟, 王祝堂. 铝在商用汽车中的应用[J]. 轻合金加工技术, 2016,44(5)：1-4.
WANG Dawei, WANG Zhutang. Appication of Aluminum in Commercial Vehicles[J]. Light Alloy Fabrication Technology, 2016, 44(5)：1-4.
[3]MA Congcheng，LAN Fengchong. Application of Comprehensive Optimization into Bus Structure Lightweight Improvement in 3-Section[C]∥Chassis Frame Proceedings of the FISITA 2012 World Automotive Congress. Berlin, 2013：1023-1031.
[4]RAO S, BHATTU A. Dynamic Analysis and Design Optimization of Automobile Chassis Frame Using FEM[C]∥Proceedings of iNaCoMM 2017. Singapore, 2019：671-680.
[5]LI Shunming, XU Kun, WANG Jinrui. The Light Weight Design of Mowing Vehicle Frame with a Combined Method[J]. Modern Mechanical Engineering, 2018, 8(3)：192-203.
[6]王海光. 重型货车车架静动态特性分析与优化设计[D]. 重庆：重庆交通大学, 2016.
WANG Haiguang. The Static Dynamic Characteristics Analysis and Optimization Design of a Heavy Truck Frame[D]. Chongqing：Chongqing Jiaotong University, 2016.
[7]龙凯, 谷先广, 王选. 基于多相材料的连续体结构动态轻量化设计方法[J]. 航空学报, 2017, 38(10)：129-138.
LONG Kai, GU Xianguang, WANG Xuan. Lightweight Design Method for Continuum Structure under Vibration Using Multiphase Materials[J]. Acta Aeronautica et Astronautica Sinica, 2017, 38(10)：221022.
[8]辛勇, 叶盛. 基于多目标优化的钢-铝混合轻量化车架设计[J]. 中国机械工程, 2014, 25(17):2402-2407.
XIN Yong, YE Sheng. Design of Steel-aluminum Hybrid Lightweight Frame by Muti-objective Optimization[J]. China Mechanical Engineering, 2014, 25(17)：2402-2407.
[9]周云郊. 钢铝混合材料车身结构轻量化设计关键问题与应用研究[D]. 广州：华南理工大学, 2011.
ZHOU Yunjiao. Studyon Several Key Problems of Lightweight Design for Steel-aluminum Hybrid Structure Car Body and Its Applications[D]. Guangzhou：South China University of Technology, 2011.
[10]LI Jing, CHENG Xu, LIU Dong, et al. Phase Evolution of a Heat-treatable Aluminum Alloy during Laser Additive Manufacturing[J]. Materials Letters, 2017, 214:56-59.
[11]潘高元, 李舜酩, 朱彦祺. 四缸柴油机油底壳噪声预测与降噪研究[J]. 噪声与振动控制, 2018, 38(3)：216-220.
PAN Gaoyuan, LI Shunming, ZHU Yanqi. Study on Noise Prediction and Reduction of Oil Pan of a Four-cylinder Diesel Engine[J]. Noise and Vibration Control, 2018, 38(3)：216-220.
[12]单喜乐. 某重型汽车车架抗疲劳轻量化设计[D]. 长沙：湖南大学, 2018.
SHAN Xile. Anti-fatigue and Lightweight Design for Frame Structure of a Heavy Truck[D].Changsha：Hunan University, 2018.
[13]张袁元, 李舜酩, 刘晓伟, 等. 基于模态与遗传优化的某卡车振动特性分析[J]. 南京航空航天大学学报, 2011, 43(6):841-845.
ZHANG Yuanyuan, LI Shunming, LIU Xiaowei, et al. Vibration Characteristics Analysis and System Optimization of Vehicle Based on Genetic Algorithm and Modal[J]. Journal of Nanjing University of Aeronautics & Astronautics, 2011, 43(6)：

841-845.
[14]谢锋. 基于近似模型的车架不确定性多目标优化[D]. 长沙：湖南大学, 2013.
XIE Feng. Uncertainty Multi-objective Optimization of Frame Based on Approximate Model[D].Changsha：Hunan University, 2013.
[15]王凤昕. WD52PC型注吹机下模板的断裂失效分析及基于HyperWorks的优化改进[D]. 南宁：广西大学, 2015.
WANG Fengxin. Injection Blow Molding Machine Type of WD52PC and Improvement Based on Hyper Works[D].Nanning：Guangxi University, 2015.
[16]夏人伟. 工程优化理论与算法[M]. 北京：北京航空航天大学出版社, 2003.
XIA Renwei. Engineering. Optimization Theory and Algorithm[M]. Beijing：Beijing University of Aeronautics and Astronautics Press, 2003.
[17]兰凤崇, 钟阳, 庄良飘, 等. 基于自适应响应面法的车身前部吸能部件优化[J]. 汽车工程, 2010(5):404-408.
LAN Fengchong, ZHONG Yang, ZHUANG Liangpiao, et al.Optimization of Energy-absorbing Members in Front-end of Car Body Based on Adaptive Response Surface Method[J].Automotiove Engineering, 2010(5):404-408.
[18]杨春兰, 张亚丽, 黄伟,等. 新型电动汽车车架结构分析及优化设计[J]. 机械设计与制造, 2017(6):234-237.
YANG Chunlan, ZHANG Yali, HUANG Wei, et al. Structure Analysis and Optimization of a New Type Electric Vehicle Frame[J]. Machinery Design&Man-ufacture, 2017(6):234-237.
[19]黄妮, 张志超, 戴作强, 等. 氢燃料电池客车车架动态特性分析与优化研究[J]. 制造业自动化, 2019, 41(1)：93-98.
HUANG Ni,ZHANG Zhichao, DAI Zuoqiang,et al. Dynamic Characteristics Analysis and Optimization of Hydrogen Fuel Cell Bus Frame[J]. Manufacturing Automation, 2019, 41(1)：93-98.
[20]周文. 重型货车车架有限元分析与结构优化[D]. 淮南：安徽理工大学, 2017.
ZHOU Wen.The Finite Element Analysis and Structure Optimization of Heavy Truck[D]. Huainan：Anhui University of Science and Technology, 2017.
[21]CHINCHULUUN A， PARDALOS A， MIGDALAS A， et al. Pareto Optimality, Game Theory and Equilibria[M]. Berlin:Springer, 2008.