Research On The Exploitation Of Aluminum Alloy Vacuum Die-casting Part For The Lightweight Coach Body

Safety, environmental protection and energy saving are the eternal topics of auto development, especially in the time while the gross of automobile have risen sharply, a serious threat to the environment and energy shortages, it is important to decrease the weight of automotive. As a main direction of auto development, the lightweight coach which use aluminum instead of steel body have been more and more attention. However, the lightweight coach is remain at the stage of experimentation interiorly, that is because they haven't found an effective measure to resolve the problem that the body is out of strength due to a diversity of body components and the quality of refractory, also because of many limitation in the position of connecting, One of the subject of cooperative enterprises who have interrupted study on all-aluminum body fracture due to bar fracture a few years ago.In allusion to the above-mentioned problems and the needs of enterprises, this paper carry out the key technologies of lightweight coach, that is the exploitation of aluminum alloy vacuum part ,and first focus on the characteristics of the existing bus body structure, then transform the steel parts of the original body in the luggage compartment of body classis to aluminum component which have a uniform section and design an aluminum alloy connecting part which has a special connector for the join between aluminum alloy profile and steel part. In order to realize the connection between steel and aluminum joints, this paper adopt the rivet connection by comparing the characteristics of a variety of connection and checking. After CAE analysis, we found that the intensity of aluminum alloy profile and connecting part meet to the requirement, and these have resolved the problem of multi-species bar and the connection between parts.Secondly, in the exploitation of connecting part mould, this article designs a moldbase which can use for different parts. For the sake of high-strength and high production quality of the connecting part, we use a vacuum die-casting technology and mold CAE to assist the design of mold casting system and vacuum channel.Finally, we manufacture the aluminum alloy connecting part and test its size and mechanical properties. The test results show that the quality of the vacuum die-casting cast after heat treatment meet to all the requests by design, and this shows that the exploitation project of aluminum alloy connecting part is feasible. This paper also proposes a design and production specification of the aluminum alloy die-casting, and it can be used for the design and production of other parts.