Heavy Truck Cab Suspension Casting Optimization

In the context of automotive lightweight, Star Kaima produced by Hualing Company was about 800KG heavier than other truck of the same model ,this restricted the market of Star Kaima. The cab mounting casting was made by steel, it is the important unit connecting the cab with the frame. The optimization of lightweight about the casting was so urgent as the important part of the lightweight of the whole truck.This paper first introduced the meaning and the major study approaches about the truck lightweight in the context of the development of the auto industry. Then combined with the status of the overweight of the Star Kaima, we proposed the goal of the optimization of the cab mounting casting. By studying the theory of the design and optimization of the structure of the cab mount, we analysis the stress and the strength of the cab mount bracket in the front suspension upper and lower parts. And we proposed the objectives and strategies of the design and optimization, and we determined the optimal design solution. Using the software of HyperWorks based on the theory of FEM optimization, we modeled and designed the cab mount bracket in the front suspension upper and lower parts, and we got the result of the optimal design. By analyzing the stress and the strength before and after the optimization and doing the real vehicle collision tests, we verified the result and confirmed the truth that the casting after optimization was filling the product standard and the needing of all kinds stuation.In this paper, combining of the cooperation of Anhui Hualing Automobile Co.,ltd. and the college of Mechanical and Vehicle Engineering of Hunan university, we proposed the method of optimization in the heavy-duty trucks and related casting lightweight design optimization of the design in the heavy-duty trucks and related casting lightweight design optimization of the design has some practical value and development prospects.