Research On The Development Technology Of Aluminum-plastic Combinative Trunk Lid

In recent years,with the development of science and technology,auto industry has gotten a strong promoted. It made a great progress in research, production marketing and other fields. Auto industry has become one of the most important industries in national economy. More and more families have gotten their domestic cars. However, some severe problems has become more and more obvious, the severest of them are resource and environment. To solve these problems,all the auto manufacturer are working on the solution. As everybody knows, the lightweight design is a useful method for solving these problems,and body is the biggest part of a car ,make up 40%~60% of the weight of a car. So it is very important to lessen the weight of bodies.With the popularization of computer in engineering, some technology such as CAD, CAE has been used expertly. The advantage of simulation by computer and struct optimazation has been tested and verified in the producting of cars. The development of material science has a great influence to auto industry, many kinds of new material is being used in cars now. High-strength steel, Aluminum alloy, Magnesium alloy, engineering plastic are used more universally because of their excellent mechanical character. These kinds of material can not only meet the operating requirement, but also make the cars lighter.This thesis is based on the use of these new material and technology, use finite-element method and topology optimazation to draw up a development technology of Aluminum-Plastic combinative trunk lid. The details are:(1) This thesis introduced the condition that the new kinds of material are used and the theory of struct optimazation. And chose the fit material for the new struct. Alufer 6061 for the framework, PC/PBT for the outside board and PA66 for the inside board.(2) Made a detailed introduce for the theory of finite-element method and the CAE software HyperWorks which was used in this project.(3)Made a FEM model for the trunk lid, and described the principle, method and procedure of making FEM model.(4) Described the theory of model analysis and statics stiffness analysis. And analysised the built FEM model in above methods. We have gotten the data about the basic property of the trunk lid, these data would guide the next step of the design of the new struct.(5) Made a introduction for topology optimization. The result of statics stiffness analysis would be the constraint condition. The main shape of the trunk lid would be the basic struct of the topology optimization. Then designed a alufer framework which could fill the bill of statics stiffness.(6)Redesigned the inside board to fill the operating requirement, replaced the material of both inside and outside board(PC/PBT for the outside board and PA66 for the inside board). Assembled the components and made a size optimization for the boards based on the 1st mode frequency as the constraint condition.(7) After determining the sizes of these components, the new struct design had been finished. Then contrasted the functions of the new one and the intrinsical one to confirm that the new struct could fill the operating requirement and prove the prominent effect on lightweight.(8) Summarized an intact and open expansion path in production of Aluminum-Plastic combinative trunk lid and have made a particular introduction of the path. Told the advantage and disadvantage of the path. Define our directions to the next step of research on this technology.