铝合金汽车前碰撞横梁的轻量化设计与碰撞性能分析

摘要

基于显式动力学有限元分析软件,以混合细胞自动机(HCA)作为优化计算模型,对铝合金前碰撞横梁的结构进行优化设计.针对拓扑优化结果,采用模拟退火法优化横梁壁厚尺寸,获得薄壁、中空且带有加强筋结构的铝合金前碰撞横梁设计方案.以6061铝合金前碰撞横梁替代某车型原钢质横梁,通过台车碰撞进行仿真模拟与实验验证.结果表明:铝合金前碰撞横梁比原钢质前碰撞横梁质量减轻了25％,且具有较高的抗弯曲强度,低速碰撞下,铝合金前碰撞横梁较原钢质件系统吸能提高了45.6％.%The finite element analysis software based on explicit dynamic method was applied to the topology optimization of aluminum bumper using hybrid cellular automata (HCA) as an optimizing model. The results of topology optimization show that the simulated annealing method can be used for the optimization design of the bumper thickness, and the thin-walled, hollow aluminum bumper with reinforced ribs is obtained. The original steel bumper was replaced by 6061 aluminum alloy. Both the car crash simulation and experiment were performed. The results indicate that the mass of aluminum bumper is 25% lighter than that of the original steel bumper. The aluminum bumper has higher flexural strength than the original steel bumper. At the same time, the crash energy absorption of the aluminum bumper system is 45.6% higher than that of the original steel bumper system in low-speed collision.