Lightweight Design And Research Of Precision Cast Aluminum Bumper

Due to the rapid development of automobile industry in China,the pollution problem is becoming more and more serious,which brings serious environmental and energy problems.The study shows that for every 10% reduction in weight of a car,fuel consumption can be reduced by 8%~10%,and light weight of the car is one of the important directions for the development of the automobile industry.Precision casting aluminum alloy products,because of its "big","thin","fine" characteristics,gradually become the trend of the development of parts and components.In this paper,the research on the replacement of steel bumper with cast aluminum bumper from the aspects of reverse modeling,performance analysis,product design,structural optimization and casting simulation is carried out for the important parts of the car body-bumper.In this paper,the bumper on the vehicle is removed for 3D scanning,the three-dimensional model and the finite element model are established,and the performance analysis is carried out.On the basis of this,the structure optimization of the re-designed cast aluminum bumper is carried out,and the gating system design of the cast aluminum bumper is carried out at the end of the paper.Simulate the pouring process and analyze the state of the product.The main contents are as follows:Firstly,the three-dimensional model of bumper is established by three-dimensional scanning reverse modeling,and the finite element model of low-speed impact between pendulum and bumper is established.The accuracy of bumper model is verified by experiments.The response characteristics of bumper in 4km/h front collision and 2.5km/h bias collision are analyzed.Evaluating the impact performance of the original bumper.Secondly,based on the casting design criteria,re-design the cast aluminum bumper.On the one hand,the front beam is designed by topology optimization of the three-point constraint condition of the front beam of the bumper.On the other hand,by comparing different schemes,the structure with the optimal energy absorption characteristics is selected as the energy absorbing box of the cast aluminum bumper.Finally establish a new cast aluminum bumper structure.Taking the performance of the original bumper as the objective,the thickness of three groups of different parts of the new cast aluminum bumper is used as the optimization variable,the response surface model is established by using the central composite design,and the influence of each variable on the response is analyzed,and the optimal scheme is selected.Compared with steel bumper,achieve lightweight effect FruitFinally,the form of the gating system is designed and the size of the gating system is determined by calculation.The numerical simulation of the designed gating system is carried out to analyze the state change of the castings,predict the shrinkage of the castings and ensure the quality of the castings.The results show that the designed cast aluminum bumper not only improves the performance of the original bumper,but also reduces the weight by 35%,and the lightweight effect is remarkable.