Lightweight Research Of A Commercial Vehicle Frame Based On Optistruct

Because of the urgency of environmental problems and the shortage of resources,energy saving and emission reduction of car people attach importance to the gradual development of the modern automobile,the lightweight,intelligent direction,automotive lightweight technology has become a hot field of automotive research at home and abroad.The frame is the load bearing and transmission component of the commercial vehicle,the main function is to bear a large number of impact and complex loads,which affect the performance of the vehicle.How to use the frame,under the premise of ensuring safety performance and cost control,lightweight organic combination of lightweight design technology,new material technology,the manufacturing process of the three technologies to realize the frame,become the automotive technology research and development direction.Although effectively reduce the vehicle quality by using new materials,but these new material manufacturing process complex,high cost,so a short period of time to use in cars,so the lightweight design technology is a hot topic at present.Because the current research mainly focused on the lightweight body;the majority of lightweight frame of cars and buses,research on lightweight frame to heavy vehicles and special vehicles is still less,so it is particularly important to study on lightweight truck frame.This paper mainly from the following aspects of the relevant research:1.Frame finite element modeling.To simplify,the reasonable model of the frame geometry clean in Hyperworks software,select the appropriate cell size of finite element mesh of the frame;the combination use of beam element and rigid unit to simulate the rivet and bolt frame components connected between the connecting frame welding between components is simulated with the Rigid element,REB3 simulation of quality the connection point,establish a finite element model of the frame assembly.2.Frame static analysis.In order to predict the fatigue of the frame in the use of the damage and bearing capacity,stiffness analysis of the frame in Hypermesh software and analysis to four conditions of strength in the dynamic load,driving,braking and processing results in Hyperview,deformation of the frame stiffness and strength under four working conditions and stress and deformation analysis,and the stress of the frame,find the maximum stress and maximum deformation.By calculating the bending stiffness and torsional stiffness of the frame and the safety factor,the static characteristics of the frame are evaluated.The results show that the strength and stiffness of the truck frame meet the requirements and have the potential of lightweight.3.Modal analysis and experimental verification of frame.The finite element model of frame by frame based on modal analysis of the frame structure can be obtained the natural frequency and vibration mode,and the frame of comparative analysis of the real vehicle test results and numerical modal analysis results,in order to prevent the frame and engine excitation input in random road conditions caused the resonance of the chassis to provide a theoretical basis.To provide a reliable reference for the optimal design of the follow-up frame.4.Lightweight design of frame based on CAE technology.The size of frame structure optimization objective is to obtain the best combination of plate thickness,this paper first analyzes the frame sensitivity of frame structure,research the influence of plate thickness on the response variables,select some high sensitivity thickness variable as the size optimization design variables,set the objective function and constraints,the establishment of size optimization design mathematical model of size optimization of the frame;then the strength and modal stiffness check to verify the design scheme of frame structure optimization,the analysis results show that the frame in order to meet the performance constraint,the optimized frame size compared to the original quality of the frame is reduced by 8.25% and lost 4.22% for adjustment plate thickness is commonly used in steel frame the original quality of the frame,so that the weight of the frame,the frame lightweight ideas in this article is feasible,for the future design of frame,Optimization has certain reference significance.