Optimal Design On Structure And Forming Process For Lightweight Of Automobile Seats

With the increase of automobile, the contradiction between cars andenvironmental protection has become the main problems which restrict thesustainable development of the auto industry. In the face of the arrival of lowcarbon era and the great pressure of energy saving and emission reduction,lightweight of automobile is one of the most effective and realistic ways to solvethis problem, so as to promote the application and development of new material andtechnology in automobile industry. Among them, the most remarkable is theapplication and development of aluminum alloy in lightweight of automobile.The paper starts with the lightweight material of framework of seat, OptimalStructure Designing, forming process, and so on to study the lightweight ofautomobile seat. The static strength of steel seat and aluminum alloy seatframework have been simulated by FEM (finite element method) to demonstrate thefeasibility of substitution from steel to aluminum alloy, and optimal structuredesigning was simulated based on the analysis of the results. At the same time, thelow pressure casting process of aluminum alloy seat backrest framework has beensimulated by FEM. The main content is as follows:First, based on the reading of a mass of literature and deep research, thelightweight of automobile and its realization, the design method and developmenttrend of lightweight of automobile seat have been introduced, as well as theapplication of low pressure casting in the lightweight of automobile. According tothe conditions of the group, Hyperworks has been chosen as the analysis softwareon static strength, and Procast software has been chosen to simulate casting process.After digesting and absorbing the usage method of these soft wares, I mastered thegeneral method of creating finite element metadata of seat, simulating staticstrength of seat assembly and optimal process designing of seat backrestframework.Second, static strength of the steel seat has been simulated, and the originalstructure has been improved based on the analysis of the results. The results showthat the linear static strength of elliptic section of steel tube is more than the round section with same area. The structure design and finite element analysis of thealuminum alloy seat framework have been carried on, and topological optimizationof back frame has been carried out based on the analysis of the results. The researchresults show that the weight of aluminum alloy seat framework is46.6%lighterthan that of the steel, and have higher static strength.Finally, low pressure casting process of the aluminum alloy seat backrestframework has been designed and simulated by FEM, combining with orthogonaltesting, to discuss the effect of pressure, temperature, initial temperature of diesand open mold-temperature on forming quality. The optimum process parametershave been determined.The purpose of this paper is to provide useful reference for the implement oflightweight of automobile seat through the above research.