| At present,the demands for lightweight of automobile are increasing with the rising voice of weight reduction,energy saving and consumption of automobile.As an important automobile structure part,the aluminum alloy wheel hub has become the best choice for the automobile wheel hub due to its better lightweight and shock absorption effect.The structure and properties of aluminum alloy wheel hub can significantly affect the safety of vehicle operation.Therefore,study on structural optimization and properties of aluminum alloy wheel hub has important significance to improve the quality of aluminum alloy wheel hub hubs and the properties of vehicles,and to realize lightweight of vehicles and energy-saving emission reduction.The HJ309 aluminum alloy wheel hub as the research object had been studied.According to structure characteristics and performance test standard of original wheel hub,the boundary conditions of wheel hubs were determined,with dynamic bending fatigue test standard,radial fatigue test standard and 13° impact test standard.The wheel hub geometry was drawn using 3D modeling software,and the finite element analysis model of aluminum alloy wheel hub was established using the ABAQUS finite element analysis software.The simulation of structure properties of wheel hub had been analyzed according to the wheel hub property test standard.Based on the results of simulation analysis,the structure optimization and experimental verification of wheel hub were done.The results showed that the maximum stress and maximum strain of original structure wheel hub under bending loading,whose direction from the center of the window line hub 200 position,were 119.3MPa and 0.1766%;in the radial loading direction 0°(the center of the window line),the maximum stress and maximum strain of wheel hub were 128.1 MPa and 0.1693%;in the impact test,the maximum stress and maximum were 166.6MPa and 0.1874%,respectively.The maximum stress of the wheel hub occurred when the impact load occurred at the bolt hole,which was caused by the fixed constraint,and the stress value of the other parts was less than 100MPa.The stress value of the wheel hub was less than the yield strength of the material under the three test conditions.So the lightweight design of wheel hub could be conducted because structure strength was rich.Adding groove at the site of spokes could meet the demand of topology optimization of wheel hub shape.The optimum sizes of wheel hub groove were obtained using orthogonal test method that depth 35mm,length 50mm and width 28mm.Under the condition of the optimal sizes,the volume reduction rate of wheel hub could reach to 5.99%.The finite element simulation and analysis of the optimized structure of wheel hub were carried out according to the performance test standard and boundary condition of the wheel hub.Compared with the simulation results of wheel hub with original structure,the stress of optimized wheel hub slightly increased under the bending loading,the stress obviously decreased under the radial loading,while the stress slightly increases under impact loading.But the stresses of optimal wheel hub under three test conditions were not exceed the yield strength of material,and strains of wheel hub were lower,which show that the properties of optimal wheel hub could not only meet the property requirements,but also achieved the objective of lightweight of wheel hub.The fatigue test,radial fatigue test and impact test were carried out according to the performance test standard,the wheel after the test was examined by visual inspection and staining.After the testing,the wheel hub was checked by visual inspection and coloring detection method.The results of property test showed that the properties of wheel hub with optimal structure could meet the requirements of the standard,and no crack and serious deformation occurred.The test results and simulation results were in good agreement. |
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