高密度结构泡沫对汽车前纵梁耐撞性的影响及应用
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摘要
为降低偏置碰撞时乘员腿部伤害,研究了汽车前纵梁的耐撞性及其改进。对某车型几种不同前纵梁截面,进行了弯曲压溃和轴向压溃的有限元分析。作为改进,在前纵梁延伸段内填充了高密度结构泡沫,进行了偏置碰撞试验。结果表明:填充结构泡沫后,前纵梁延伸段的变形模式得到控制,并减少了碰撞对乘员舱的侵入;与普通纵梁相比,改进后的纵梁的弯曲性能(平均载荷、吸能、比吸能)和轴向传力能力,均提高近一倍;驾驶员假人右下小腿的胫骨指数由0.97降至0.38,且小腿胫骨压缩载荷也有明显降低。因此,该设计保持了乘员舱完整性,增强了整车耐撞性。
The crashworthiness of vehicle front side-rails was studied and then improved to reduce occupant leg injuries caused by offset impact. The bending crushing and axial crushing were analyzed with various sections in vehicle front side-rails using a finite element method. Improvement in the front side-rail extension, filled with high-density structural foam, was verified in an offset impact test. The results indicate that the deforming mode of the front side-rail extension is effectively controlled after filling high-density structural foam with the intrusion into the occupant cabin significantly reduced. The average load, total energy absorption, energy absorption per mass, and the axial force transmission capability are increased by nearly two times with improved front side-rail bending compared with ordinary front side-rail bending. The driver lower right leg tibia index is reduced from 0.97 to 0.38 with the driver lower leg tibia load obviously decreasing. Therefore, this design maintains the occupant cabin integrity and enhances the vehicle crashworthiness.
The crashworthiness of vehicle front side-rails was studied and then improved to reduce occupant leg injuries caused by offset impact. The bending crushing and axial crushing were analyzed with various sections in vehicle front side-rails using a finite element method. Improvement in the front side-rail extension, filled with high-density structural foam, was verified in an offset impact test. The results indicate that the deforming mode of the front side-rail extension is effectively controlled after filling high-density structural foam with the intrusion into the occupant cabin significantly reduced. The average load, total energy absorption, energy absorption per mass, and the axial force transmission capability are increased by nearly two times with improved front side-rail bending compared with ordinary front side-rail bending. The driver lower right leg tibia index is reduced from 0.97 to 0.38 with the driver lower leg tibia load obviously decreasing. Therefore, this design maintains the occupant cabin integrity and enhances the vehicle crashworthiness.
引文
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[9]Royston K,Hornung M,Hajj M,等.结构胶和结构泡沫—改善碰撞性能的可行技术(英文)[J].汽车安全与节能学报,2010,1(4):313-319.Royston K,Hornung M,Hajj M,et al.Crash Performance Enabling Technologies,Structural Adheise and Structural Foam[J].J Automotive Safety and Energy,2010,1(4):313-319.(Written in English,published in a journal of China)
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[12]刘书田,张宗华.新型截面耐撞梁及其冲击吸能性能分析[J].应用力学学报,2009,26(2):360-364.LIU Shutian,ZHANG Zonghua.New cross-section configuration of crashworthy beam with analysis for energy absorption under impact loads[J].Chin J Appl Mechanics,2009,26(2):360-364.(in Chinese)
[13]余跃,周鸿波,童水光,等.一种薄壁梁加强结构及其动态抗弯性能分析[J].机械设计,2011,28(3):80-83.YU Yue,ZHOU Hongbo,TONG Shuiguang,et al.An thin-walled beam enforcement structure and its dynamic bending performance analysis[J].J Machine Design,2011,28(3):80-83.(in Chinese)
[14]王青春,范子杰,桂良进,等.泡沫铝填充帽型结构轴向冲击吸能特性的试验研究[J].机械工程学报,2006,42(4):101-106.WANG Qingchun,FAN Zijie,GUI Liangjin,et al.Experimental studies on the axial crash behaviour of aluminium foam-filled hat sections[J].Chin J Mechanical Eng,2006,42(4):101-106.(in Chinese)
[2]白中浩,陈天志,曹立波,等.基于正交设计的汽车前纵梁吸能结构的优化[J].汽车工程,2010,32(11):935-939.BAI Zhonghao,CHEN Tianzhi,CAO Libo,et al.Optimization of energy-absorbing structure of vehicle front side rail based on orthogonal design[J].Automotive Engineering,2010,32(11):935-939.(in Chinese)
[3]简坚得,兰凤崇,饶建强,等.利用蜂窝结构改善汽车耐撞性的仿真研究[J].汽车技术,2010(4):21-24.JIAN Jiande,LAN Fengchong,RAO Jianqiang,et al.A simulation study on improving vehicle crashworthiness with honeycomb structure[J].Automobile Technology,2010(4):21-24.(in Chinese)
[4]王华锋,王宏雁,陈君毅.车用结构胶弹塑性本构方程的试验与仿真研究[J].汽车工程,2012,34(2):154-158.WANG Huafeng,WANG Hongyan,CHEN Junyi.Experimental study and simulation on the elastic-plastic constitutive equations of vehicle structural adhesives[J].Automotive Engineering,2012,34(2):154-158.(in Chinese)
[5]张涛,李光耀,陈涛.基于耐撞性的前纵梁焊点模拟及其优化设计[J].汽车工程,2010,32(6):524-529.ZHANG Tao,LI Guangyao,CHEN Tao.Modeling and optimization design of the spotweld on front side rail based on crashworthiness[J].Automotive Engineering,2010,32(6):524-529.(in Chinese)
[6]陈更,陈君毅,王宏雁,等.胶接、点焊和胶焊连接方式的前纵梁耐撞性分析[J].汽车安全与节能学报,2012,3(1):38-43.CHEN Geng,CHEN Junyi,WANG Hongyan,et al.Crashworthiness analysis of spot-welded,adhesively bonded and bonded-welded front longitudinal beams[J].J Automotive Safety and Energy,2012,3(1):38-43.(in Chinese)
[7]冯美斌.汽车轻量化技术中新材料的发展及应用[J].汽车工程,2006,28(3):213-220.FENG Meibin.Development and applications of new materials in automotive lightweighting techonlogies[J].Automotive Engineering,2006,28(3):213-220.(in Chinese)
[8]陈晓斌.基于现代设计方法和提高整车碰撞安全性的车身轻量化研究[D].长春:吉林大学,2011.CHEN Xiaobin.Study on car body’s lightweight based on advanced theories and improving vehicle’s safety performance[D].Changchun:Jilin University,2011.(in Chinese)
[9]Royston K,Hornung M,Hajj M,等.结构胶和结构泡沫—改善碰撞性能的可行技术(英文)[J].汽车安全与节能学报,2010,1(4):313-319.Royston K,Hornung M,Hajj M,et al.Crash Performance Enabling Technologies,Structural Adheise and Structural Foam[J].J Automotive Safety and Energy,2010,1(4):313-319.(Written in English,published in a journal of China)
[10]DOW Automotive Systems.Body structural foam technologies[EB/OL].(2010-10-01).www.dowautomotive.com.
[11]Ishida K,Fukahori M,Hanakawa K,et al.Development of a technique to strengthen body frame with structural foam[R].SAE Paper,2001-01-0313.
[12]刘书田,张宗华.新型截面耐撞梁及其冲击吸能性能分析[J].应用力学学报,2009,26(2):360-364.LIU Shutian,ZHANG Zonghua.New cross-section configuration of crashworthy beam with analysis for energy absorption under impact loads[J].Chin J Appl Mechanics,2009,26(2):360-364.(in Chinese)
[13]余跃,周鸿波,童水光,等.一种薄壁梁加强结构及其动态抗弯性能分析[J].机械设计,2011,28(3):80-83.YU Yue,ZHOU Hongbo,TONG Shuiguang,et al.An thin-walled beam enforcement structure and its dynamic bending performance analysis[J].J Machine Design,2011,28(3):80-83.(in Chinese)
[14]王青春,范子杰,桂良进,等.泡沫铝填充帽型结构轴向冲击吸能特性的试验研究[J].机械工程学报,2006,42(4):101-106.WANG Qingchun,FAN Zijie,GUI Liangjin,et al.Experimental studies on the axial crash behaviour of aluminium foam-filled hat sections[J].Chin J Mechanical Eng,2006,42(4):101-106.(in Chinese)