Design And Analysis On GMF-NEV Instrument Panel And Parts Of All Plastic Body

With the growing proportion of the polymer material in automobile, more and more engineering plastics has been used in the car body. All plastic body is not simply formed by polymer material instead of metal, but formed with metal frame inside with polymer material surrounded. Automotive plastics is the future trend of lightweight. At present, there is still no systematic program of formation lightweight design, in order to solve this problem, a research was taken in this paper. The automobile body is mainly composited of engine cover, car roof, body, trunk lid and so on. Due to the large amount of body design engineering, the paper mainly studies the lightweight design of the trunk lid and instrument panel system.The main contents are as following:(1) In order to meet the noise, vibration and harshness (NVH) requirement, the vibration of instrument panels should be reduced. With rotational molding process we replace the injection molding in the process of I/P, according to the modal analysis of I/P.(2) With the CFD software, the internal fluid flow of all plastic car air-conditioning duct had been analyzed. In order to solve the non-uniform flow distribution of fluid, the air duct bifurcation branch had been adjusted. What was more, a conversion interface had been added near the inlet location. According to the result of comparison, the best structure was chosen.(3) In order to meet the needs of automotive lightweight, high-molecular materials are used to replace original metal stamping parts, ensuring the trunk lid features an ergonomic base. Meanwhile, plastic trunk lid molding process were optimized to meet the demand for rotary molding, including stress calculation and optimized design of metal inserts.(4) With the purpose of verifying whether the installation location of pneumatic spring installed on all plastic car body and parameters could meet the demand of normal use and man-machine engineering, motion simulation analysis was used for the special structure design of all plastic car body and all plastic trunk. Coordinate tracking method had been used in this study based on NX software. The centroid of car trunk was first to be determined so as to identify the general location of pneumatic spring, then maximum angel of pneumatic spring could be obtained through NX motion simulation, and then the two circle method was used to determine the specific installation location of pneumatic spring, finally the torque and the power that people used to open or close the car trunk could be calculated by coordinate tracking method. Using the methods described, it was possible to verify the final location and parameters of pneumatic spring for the actual engineering application.