Aluminum Alloy Lightweight Design For Automobile Brake Shoe

In recent years,with the rapid development of automobile industry,and the transportation conditions continue to improve,the automobile industry has become one of the most important traffic,transportation tool in people daily life.But with the development,the energy,environmental problems have become increasingly prominent caused,therefore the domestic and foreign automobile enterprises have put forward "The lightweight design concept of automotive".As an important component of the drum brake,brake shoe is one of the important safety parts.Although in recent years brake shoe has been in development,but most of them focus on the improvement of the existing structures or optimization of existing materials,lightweight research process is relatively slow.New,the brake shoe basic model of QT450 material provided customers is to the premise,through the combination of the finite element simulation technology and orthogonal test theory,the lightweight design of aluminum alloy is to the brake shoe.Through the research between the working principle of drum brake and the mechanics theory of brake shoe,and reference customers the performance parameters of brake shoe material,determine the lightweight design of brake shoe of aluminum alloy material type and related material properties.With the experiment to study the high temperature mechanical properties of lightweight materials of ZL205 A aluminum alloy casting,including: elastic model,high temperature strength,thermal recession.With the characteristics and analysis process based on the Ansys Workbench finite element simulation software,combined with the actual working condition and load conditions of the drum brake,determine the design scheme of the transient dynamic analysis of brake shoe.Includes: pretreatment,constraint set,load applied,after processing settings.With finite element analysis of QT450 material of brake shoe provided by customers,to verify the accuracy of the finite element analysis program,and to determine the design reference of lightweight brake shoe of aluminum alloy.For example,the maximum yield strength is designed of 345 MPa,the maximum deformation is designed of 1.7 mm,the safety margin is 10 %,the fatigue life is 200 thousand times.In this paper,comprehensive considerationa the evaluation standard of brake shoe,and the influence factors of the structure.Using the orthogonal test theory to analysis the lightweight design of brake shoe structure with equivalent stress and maximum deformation.Comprehensive consideration to make sure the optimum combination factors of brake shoe structure is: draft angle is 1.5 degrees,the important position to stiffener thickness is 6 mm,the non important position to stiffener thickness is 4 mm,the chamfer designed as R10,the curvature of vertical rib increases 5 mm,the outer arc designs of triangular hole,vertical ribs without holes,inner arc thickness does not increase.Compared with the design basis,determine the brake shoe structure optimization scheme,to further remove the stress concentration,and improve the overall strength,stiffness of brake shoe.New,to make sure the optimal structure of brake shoe for quality is 4.011 kg,the equivalent stress is 260.5 MPa,the maximum deformation is 1.705 mm.