Research On Light Weight Design And Impact Safety For SUV Frame Based On Filling Aluminum Foam In Longitudinal Beam

Non-bearing type structure is widely used in automotive body currently for the frame stiffness, high strength, and vehicle reliability. But there are also problems about weight and collision safety and other aspects. This paper for non-bearing body structure, namely the SUV frame of lightweight improvement started a comprehensive analysis about the weight decreasing, stiffness, modal and collision safety from two main aspects of structure and material, with the will to make foam aluminum in frame structure to prevent structure from deformation and bring in light weight advantages. Through the reasonable layout of plate thickness and optimization, the improved frame is lighter and safer. This exploration is a new structural measure for frame optimization, and its future applications will do great effect to commercial vehicle industry of China in lightweight and safety design, and the paper also provides a new way of lightweight thinking.Based on the understanding of the structure characteristics of aluminum foam, the paper briefly describes the method of reducing the thickness of the outer layer steel and reducing the structure weight and maintaining or improving the structure performance. Establish finite element model, and the validity of the model is demonstrated by comparing the results with the experimental results. With reference to the results of theoretical calculation of longitudinal plate thickness adjustment, contrast weight preliminary show that filled frame weight is reduced by about 10% than the original frame; the simulation results show the results can meet the requirements.The thickness distribution and numerical optimization design method for the size of the thickness of the steel plate is described, optimization results show that most of the thickness of the steel plate decreases, the quality of the frame reduced. The results show that the optimized frame stiffness and modal performance also meet the requirements.The impact of the original and filled frame is compared and verified, the overall deformation of the filled frame can produce more folds to absorb more energy, and can make the hollow structure of the rear part which can’t play the role of the absorption before to do effect to the collision energy absorption, while the foam aluminum is far higher than other parts in the energy absorption effect, this can do help to reducing occupant injury.