钢铝混合材料车身结构轻量化设计关键问题与应用研究
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摘要
车身的轻量化对于整车的轻量化起着举足轻重的作用,是提高汽车燃油经济性、降低有害排放最为有效的手段之一。相比于传统的单一钢质材料白车身,钢铝混合材料车身结构的理念能较好地兼顾各方面的要求,寻求轻量化效果、工艺性、安全性和成本等总体上的最优化,代表了今后汽车车身结构发展的最新趋势。钢铝混合车身是指在传统钢结构车身骨架中,将某些结构件用高强度钢板和铝合金等轻质材料替代,以充分发挥高强度钢板在强度和价格方面的优势,同时兼顾铝合金板材在减重及吸能方面的优势,通过材料和结构的优化设计和性能模拟的方法确定不同材料分布的部位,在提高成本不大的前提下实现车身高强度和轻量化,其核心理念是“合适的材料应用于合适的部位”。这种思想采取材料替换与结构改进相结合的方法,是车身轻量化的两种根本途径相结合的典型应用,完全符合车身轻量化的发展技术路线。
剖析了单一材料白车身结构的开发流程与开发方法,并在此基础上提出了钢铝混合材料车身结构的开发流程。针对钢铝异种材料的匹配优化问题,提出了材料类型和板件厚度组合优化问题的理论模型,并进一步给出了基于近似模型的优化求解方法。基于钢铝混合材料单帽型薄壁梁结构的轻量化和耐撞性多目标优化这一测试案例,从拟合精度、优化预测精度两个方面对包括二次多项式、Kriging、径向基函数(RBF)等在内的近似模型解决该问题的适用性进行了探讨,结果表明:径向基函数近似模型更适合作为近似模型来解决材料类型和板厚组合优化问题。
为解决钢铝混合车身面临的异种材料间的连接问题,以汽车车身上常用的高强度钢板SPFC590和铝合金A5052-H34为研究对象,对钢铝异种材料压力连接的可行性进行了试验研究与仿真分析,试验与仿真结果均证实了其可行性。在此基础上,以压力连接模具关键几何参数为设计变量,对连接点的颈厚值和自锁值进行了多目标优化,得到了两个目标的Pareto前沿解集,并结合实验中接头的失效模式,提出了推荐的优化方案。
以单帽型薄壁梁碰撞吸能为算例,在同等质量相同压溃长度的条件下,比较了几种常用牌号的高强度钢和铝合金的吸能特性,得出同等质量的铝合金比高强度钢吸收能量多的结论;继而以某SUV实车结构中S型前纵梁为研究对象,通过将纵梁前后端材料分别以铝合金和高强度钢替换,研究了铝合金所占纵梁总长度比例、铝合金材料类型和厚度、先进高强度钢材料类型和厚度共5个因素对钢铝混合S型前纵梁抗撞特性的影响。结果表明,钢铝混合S型前纵梁这一特殊结构能够在减少重量的同时使其吸能增加,且碰撞峰值力降低。
基于Euro NCAP正面40%重叠可变形壁障碰撞法规,建立了某SUV车身结构碰撞仿真模型,并通过实车碰撞实验,从车身结构变形和整车碰撞加速度两个方面对仿真结果进行对比研究,验证了仿真模型的可靠性。为减少单次计算时间,建立了车身前端结构的简化模型,分析了钢铝混合S型前纵梁结构应用于简化模型的碰撞特性,在此基础上,以简化模型中的前保险杠、吸能盒、副车架前横梁、前纵梁后端等构件为对象,采用均匀实验设计与RBF近似模型,建立了综合考虑总质量、总吸能、白车身扭转刚度、前纵梁后端峰值碰撞力等性能在内的钢铝混合材料与板厚组合多目标优化问题的数学模型。多目标优化方案应用于整车40%偏置碰撞环境下的仿真结果表明,钢铝混合材料设计能够在改善汽车碰撞安全性的同时,明显提高车身结构的轻量化水平,最终取得了使研究对象减重29.1%的轻量化效果。
The lightweight of car body plays an important role in the development of lightweight vehicles, and it is one of the most effective methods for improving vehicle fuel economy and reducing harmful emissions. Compared to the traditional car body with mono steel material, the new concept of steel-aluminum hybrid car body structures can better take into account all aspects of requirements for lightweight effect, technology, crash safety, cost, et al. It represents the latest trends of the future development of car body structures. The meaning of steel-aluminum hybrid structure car-body is that for the traditional steel car-body frame structure, some parts are replaced by new lightweight materials, such as high strength steel (HSS), aluminum alloy sheets, to realize the high-strength and lightweight requirements under the premise of controlling the cost rise in a reasonable level. This kind of car-body structure can make full use of price, high strength and stiffness advantages of HSS, as well as lightweight and energy absorption advantages of aluminum alloy sheets. Its core idea is: according to the principle that the appropriate materials are used for the appropriate parts, for each specially selected car-body part, to determine its optimal material and structural dimensions. By adopting the methods of material replacement and structural improvement, this new concept is a typical application to the combination of two basic ways of the car body lightweight, and it completely conforms to the technology roadmap of car body lightweight development.
Based on the analysis of the development process and methodology of traditional BIW with mono steel material, this paper proposes the development process and development methodology of the steel-aluminum hybrid materials BIW. Aiming at the matching and optimization problem of steel-aluminum hybrid materials, the theoretical model of combinational optimization of material selection and structural size for steel-aluminum hybrid car body is established and the approximate model-based optimization solution method is further given. Based on the test case concerning the multi-objective optimization for the lightweight and crashworthiness of a single-hat thin-walled beam made of steel-aluminum hybrid materials, three kinds of metamodels including quadratic polynomial, Kriging and radial basis function (RBF) are considered to solve such kind of combinational optimization problem, and their feasibility and suitability are emphatically investigated. The result shows that RBF is more suitable to be used as metamodel to solve the problem concerning material types and sheet thickness.
In order to solve the problems of the connection between dissimilar materials in the steel–aluminum hybrid car-body, the experimental research and finite element (FE) simulation analysis are carried out to study the feasibility of joining the sheets of HSS SPFC590 and aluminum alloy A5052-H34 which are both commonly used in car-body by using mechanical clinching. Based on the feasibility of experimental verification, aiming at obtaining high-quality joints with optimal properties in shear and tensile strength, the multi-objective optimization for the key geometric parameters of the clinching tool is performed by comprehensively using the methods of experimental design, statistical analysis, Meta-modeling of response surface method (RSM) and genetic algorithm (GA). The goal is to maximize both of the neck thickness and undercut value of the clinching joint. The result of solution set for Pareto front is obtained, which can provide engineers with a wide range of possible options. Taking into account the failure mode in the experiment, the relative optimum schemes are recommended.
By taking the crashworthiness of a single-hat thin-walled beam as a numerical example, the energy-absorption characteristics of several popular brands of HSS and aluminum alloys are analyzed under the condition of same mass and crushing length. The results show that the aluminum alloys can absorb more energy than HSS with the same mass. Then the crashworthiness of the S-shaped rail extracted from the frontal frame in a car is studied. In order to reduce the peak impact force while increasing the total absorbed energy, the hybrid materials are employed in that rail, where aluminum alloy is used for its front part and advanced high strength steel (AHSS) for its back. By designing 16 experiments based on orthogonal experiment, the effects of five in?uence factors with four levels on the crash performance of the steel–aluminumhybrid S-shaped front rail are emphatically investigated. These in?uence factors include the different material types of aluminum alloy and advanced high strength steel (AHSS), the sheet thicknesses of the two parts, and length proportion for the aluminum part. The research result shows that the use of steel–aluminum hybrid materials can reduce the peak impact force and the total weight for the S-shaped front rail, while the total absorbed energy can be greatly increased, so the crashworthiness and lightweight of the S-shaped front rail are significantly improved.
Based on the regulation of Euro NCAP 40% offset deformable barrier frontal crash test, the crash simulation model of a SUV is established. Through the real car crash test, the car-body deformation mode and the vehicle collision acceleration are compared with that of the simulation model, and the reliability of the FE model is verified. In order to reduce the computing time of single FE simulation, the simplified model of the vehicle front-end structures is established to replace the whole vehicle time-consuming FE model. The steel-aluminum hybrid front rail is used in that simplified model and its crash properties are analyzed. Based on the front rail made of steel-aluminum hybrid materials, the theoretical model of multi-objective optimization is established by choosing the steel-aluminum hybrid material types and the sheet thicknesses of the bumper, crash-box, cross-member of the subframe, and the back part of the front rail as the design variables. The mathematical model is based on the uniform experimental design and the RBF approximate model, and the considered performance include the total mass, total absorbed energy, torsional stiffness of BIW, peak impact force tested from the back part of the front rail. The simulation results are analyzed by applying the multi-objective optimization scheme in the 40% offset crash FE model, the results show that the optimized steel-aluminum hybrid materials can improve the vehicle crash safety, meanwhile the car-body lightweight level can also be significantly enhanced, and ultimately the total mass of the research objects are reduced by 29.1%.
剖析了单一材料白车身结构的开发流程与开发方法,并在此基础上提出了钢铝混合材料车身结构的开发流程。针对钢铝异种材料的匹配优化问题,提出了材料类型和板件厚度组合优化问题的理论模型,并进一步给出了基于近似模型的优化求解方法。基于钢铝混合材料单帽型薄壁梁结构的轻量化和耐撞性多目标优化这一测试案例,从拟合精度、优化预测精度两个方面对包括二次多项式、Kriging、径向基函数(RBF)等在内的近似模型解决该问题的适用性进行了探讨,结果表明:径向基函数近似模型更适合作为近似模型来解决材料类型和板厚组合优化问题。
为解决钢铝混合车身面临的异种材料间的连接问题,以汽车车身上常用的高强度钢板SPFC590和铝合金A5052-H34为研究对象,对钢铝异种材料压力连接的可行性进行了试验研究与仿真分析,试验与仿真结果均证实了其可行性。在此基础上,以压力连接模具关键几何参数为设计变量,对连接点的颈厚值和自锁值进行了多目标优化,得到了两个目标的Pareto前沿解集,并结合实验中接头的失效模式,提出了推荐的优化方案。
以单帽型薄壁梁碰撞吸能为算例,在同等质量相同压溃长度的条件下,比较了几种常用牌号的高强度钢和铝合金的吸能特性,得出同等质量的铝合金比高强度钢吸收能量多的结论;继而以某SUV实车结构中S型前纵梁为研究对象,通过将纵梁前后端材料分别以铝合金和高强度钢替换,研究了铝合金所占纵梁总长度比例、铝合金材料类型和厚度、先进高强度钢材料类型和厚度共5个因素对钢铝混合S型前纵梁抗撞特性的影响。结果表明,钢铝混合S型前纵梁这一特殊结构能够在减少重量的同时使其吸能增加,且碰撞峰值力降低。
基于Euro NCAP正面40%重叠可变形壁障碰撞法规,建立了某SUV车身结构碰撞仿真模型,并通过实车碰撞实验,从车身结构变形和整车碰撞加速度两个方面对仿真结果进行对比研究,验证了仿真模型的可靠性。为减少单次计算时间,建立了车身前端结构的简化模型,分析了钢铝混合S型前纵梁结构应用于简化模型的碰撞特性,在此基础上,以简化模型中的前保险杠、吸能盒、副车架前横梁、前纵梁后端等构件为对象,采用均匀实验设计与RBF近似模型,建立了综合考虑总质量、总吸能、白车身扭转刚度、前纵梁后端峰值碰撞力等性能在内的钢铝混合材料与板厚组合多目标优化问题的数学模型。多目标优化方案应用于整车40%偏置碰撞环境下的仿真结果表明,钢铝混合材料设计能够在改善汽车碰撞安全性的同时,明显提高车身结构的轻量化水平,最终取得了使研究对象减重29.1%的轻量化效果。
The lightweight of car body plays an important role in the development of lightweight vehicles, and it is one of the most effective methods for improving vehicle fuel economy and reducing harmful emissions. Compared to the traditional car body with mono steel material, the new concept of steel-aluminum hybrid car body structures can better take into account all aspects of requirements for lightweight effect, technology, crash safety, cost, et al. It represents the latest trends of the future development of car body structures. The meaning of steel-aluminum hybrid structure car-body is that for the traditional steel car-body frame structure, some parts are replaced by new lightweight materials, such as high strength steel (HSS), aluminum alloy sheets, to realize the high-strength and lightweight requirements under the premise of controlling the cost rise in a reasonable level. This kind of car-body structure can make full use of price, high strength and stiffness advantages of HSS, as well as lightweight and energy absorption advantages of aluminum alloy sheets. Its core idea is: according to the principle that the appropriate materials are used for the appropriate parts, for each specially selected car-body part, to determine its optimal material and structural dimensions. By adopting the methods of material replacement and structural improvement, this new concept is a typical application to the combination of two basic ways of the car body lightweight, and it completely conforms to the technology roadmap of car body lightweight development.
Based on the analysis of the development process and methodology of traditional BIW with mono steel material, this paper proposes the development process and development methodology of the steel-aluminum hybrid materials BIW. Aiming at the matching and optimization problem of steel-aluminum hybrid materials, the theoretical model of combinational optimization of material selection and structural size for steel-aluminum hybrid car body is established and the approximate model-based optimization solution method is further given. Based on the test case concerning the multi-objective optimization for the lightweight and crashworthiness of a single-hat thin-walled beam made of steel-aluminum hybrid materials, three kinds of metamodels including quadratic polynomial, Kriging and radial basis function (RBF) are considered to solve such kind of combinational optimization problem, and their feasibility and suitability are emphatically investigated. The result shows that RBF is more suitable to be used as metamodel to solve the problem concerning material types and sheet thickness.
In order to solve the problems of the connection between dissimilar materials in the steel–aluminum hybrid car-body, the experimental research and finite element (FE) simulation analysis are carried out to study the feasibility of joining the sheets of HSS SPFC590 and aluminum alloy A5052-H34 which are both commonly used in car-body by using mechanical clinching. Based on the feasibility of experimental verification, aiming at obtaining high-quality joints with optimal properties in shear and tensile strength, the multi-objective optimization for the key geometric parameters of the clinching tool is performed by comprehensively using the methods of experimental design, statistical analysis, Meta-modeling of response surface method (RSM) and genetic algorithm (GA). The goal is to maximize both of the neck thickness and undercut value of the clinching joint. The result of solution set for Pareto front is obtained, which can provide engineers with a wide range of possible options. Taking into account the failure mode in the experiment, the relative optimum schemes are recommended.
By taking the crashworthiness of a single-hat thin-walled beam as a numerical example, the energy-absorption characteristics of several popular brands of HSS and aluminum alloys are analyzed under the condition of same mass and crushing length. The results show that the aluminum alloys can absorb more energy than HSS with the same mass. Then the crashworthiness of the S-shaped rail extracted from the frontal frame in a car is studied. In order to reduce the peak impact force while increasing the total absorbed energy, the hybrid materials are employed in that rail, where aluminum alloy is used for its front part and advanced high strength steel (AHSS) for its back. By designing 16 experiments based on orthogonal experiment, the effects of five in?uence factors with four levels on the crash performance of the steel–aluminumhybrid S-shaped front rail are emphatically investigated. These in?uence factors include the different material types of aluminum alloy and advanced high strength steel (AHSS), the sheet thicknesses of the two parts, and length proportion for the aluminum part. The research result shows that the use of steel–aluminum hybrid materials can reduce the peak impact force and the total weight for the S-shaped front rail, while the total absorbed energy can be greatly increased, so the crashworthiness and lightweight of the S-shaped front rail are significantly improved.
Based on the regulation of Euro NCAP 40% offset deformable barrier frontal crash test, the crash simulation model of a SUV is established. Through the real car crash test, the car-body deformation mode and the vehicle collision acceleration are compared with that of the simulation model, and the reliability of the FE model is verified. In order to reduce the computing time of single FE simulation, the simplified model of the vehicle front-end structures is established to replace the whole vehicle time-consuming FE model. The steel-aluminum hybrid front rail is used in that simplified model and its crash properties are analyzed. Based on the front rail made of steel-aluminum hybrid materials, the theoretical model of multi-objective optimization is established by choosing the steel-aluminum hybrid material types and the sheet thicknesses of the bumper, crash-box, cross-member of the subframe, and the back part of the front rail as the design variables. The mathematical model is based on the uniform experimental design and the RBF approximate model, and the considered performance include the total mass, total absorbed energy, torsional stiffness of BIW, peak impact force tested from the back part of the front rail. The simulation results are analyzed by applying the multi-objective optimization scheme in the 40% offset crash FE model, the results show that the optimized steel-aluminum hybrid materials can improve the vehicle crash safety, meanwhile the car-body lightweight level can also be significantly enhanced, and ultimately the total mass of the research objects are reduced by 29.1%.
引文
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