重型商用车平衡轴支架拓扑优化设计与试制研究  

Research on Topology Optimization Design and Trial Production of Balance Shaft Bracket of a Heavy Commercial Vehicle

作　　者：白红 冀元贵 冉军 吴孟武 BAI Hong;JI Yuangui;RAN Jun;WU Mengwu(Hubei Key Laboratory of Advanced Technology for Automotive Components,Wuhan University of Technology,Wuhan 430070,China;Hubei Xingyuan Technology Co.,Ltd.,Shiyan 442000,China;Hubei Longzhong Laboratory,Xiangyang 441022,China)

机构地区：[1]武汉理工大学现代汽车零部件技术湖北省重点实验室,湖北武汉430070 [2]湖北星源科技有限公司,湖北十堰442000 [3]湖北隆中实验室,湖北襄阳441022

出　　处：《铸造技术》2023年第10期964-971,共8页Foundry Technology

基　　金：湖北省重点研发计划(2021BAA048,2022BAD100)。

摘　　要：平衡轴支架是重型商用车平衡悬架的关键零件,也是平衡悬架总成中质量占比最大的零件。针对某重型商用车现有的平衡轴支架产品质量大、制造工艺性差等问题,亟需开发出轻量化、制造工艺性良好的平衡轴支架产品。基于ANSYS Workbench平台建立该重型商用车平衡轴支架的有限元模型,对3种典型工况下的平衡轴支架进行强度分析,在此基础上采用基于变密度法的拓扑优化技术对平衡轴支架进行轻量化设计。根据结构拓扑优化结果,对平衡轴支架进行模型重构,并对优化后的结构进行强度校核。结果表明,结构优化后的平衡轴支架与优化前相比质量减轻46.5%,强度满足使用要求。最后采用铁型覆砂铸造工艺对优化后的平衡轴支架进行样件试制,制造工艺性良好,铸件质量满足要求。The balance shaft bracket is a key component of the balance suspension of heavy commercial vehicles,and the component with the largest weight proportion in the balance suspension assembly.In response to the problems of heavy weight and poor manufacturing process of the existing balance shaft bracket product for a heavy commercial vehicle,it is urgently needed to develop a lightweight and well-manufactured balance shaft bracket product.Based on the ANSYS Workbench platform,a finite element model for the balance shaft bracket of a heavy commercial vehicle was established.Strength analysis of the balance shaft bracket was conducted under three typical serving conditions.Then,a lightweight design of the balance shaft bracket was carried out by using the topology optimization technology based on the variable density method.According to the structural topology optimization result,the model of the balance shaft bracket was reconstructed,and the strength of the optimized structure was verified.The results show that the weight of the optimized structure decreases by 46.5%,and the strength meets the usage requirements.Finally,trial production of the balance shaft bracket with the optimized structure was conducted by using the sand-faced iron mould casting process.A good castability of the optimized structure is obtained and the casting quality meets the requirements.

关 键 词：重型商用车 平衡轴支架 拓扑优化 铁型覆砂铸造 

分 类 号：TG143[一般工业技术—材料科学与工程]