Finite Element Analysis And Light-weight Design Of Electric Bus Riveted Body Frame

Automotive industry is a pillar industry in modern society. With the continuous increase in automobile production and sales, the shortage of petroleum and environmental pollution become more severe. Therefore, it’s an important responsibility to develop and promote the electric vehicle. While the electric bus body frameas the main bearing components of electric bus, electric bus for total mass percent maximum,so the electric bus body frame lightweight research on reducing electric passenger car general quality,extending driving range and improving the power performance with a very significance.This paper takes a bus company research and development of electric bus riveted body frame of HFF6129G03EV as the research object, Combined with three-dimensional frame bus UG model, bus frame finite element model including the bolts between body and chassis riveting region was established in Hyperworks, Then analysis the stress distribution and displacement of passenger car under four typical working load states including Horizontal bending, limited torsion, emergency braking, emergency turning and evaluation of the body frame strength and stiffness properties. After that comprehensive evaluated the strength and the stiffness of the body frame,the strength of the bolts etween body and chassis riveting region. Meanwhile the modal analysis of bus body frame was carried out to get the natural frequency and vibration mode which was studied the dynamic characteristics of the body frame. There is margin for optimization of the bus body frame.According to the characteristics of the resistance strain gauge, the stress situations of key points on bus body franme are measured by the static experiments of the bus body. There are little errors between experimental and theoretical calculation value by comparing with the results of the finite element analysis. But the errors are in standard permission scope. Then the conclusion is that the finite element model established in this article could be proved accurate.On this basis, the mathematical model of the bus chassis was established in OptiStruct., the sensitivity analysis was performed to ascertain the influence of the change of the component’s thickness to the nature mass. In the optimization analysis, the relative sensitivity of smaller components for bus body frame were extracted as lightweight chassis design.Then compare the profermance of the bus frame bwteen before optimization and after optimization including four typical conditions and modal analysis. The results of verification by FEA show that The method proposed is feasible.