Structure Analysis And Optimization On The Base Of Automotive Master Model And Development Of Hypermesh CAE Process Automatic System

Automotive master model is a1:1simulation model produced via machine work byusing aluminum alloy according to three-dimensional numerical simulation. It is ofparamount importance for new model of car under research and development at priorperiod and quality control at later stage. As main load bearing component of master modelchecking fixture, the base is always heavy and easy distortion. Regarding to safety factors,the corporation will select overlarge security coefficient in structural design, which willcause material waste and oversize structural volume thus leading to inconvenienttransportation. Therefore, on condition that ensuring rigidity, it is quite necessary tooptimize base structure of master model checking fixture. However, there exists severalproblems while corporation is applying CAE software in practice, which has disturbed theimprovement of product development efficiency.Aiming at heavy base and easy distortion of master model checking fixture, based onFEM software HyperWorks, this paper conducts numerical simulation for base distortionand stress ability under static, hoisting and transport condition. The base structure has alsobeen improved according to simulation results. At the same time, in order to make CAEanalysis and size optimization on similar products become easier for the corporation, astandard process system of CAE analysis and size optimization pointing to checkingfixture base has been developed, which specifies operation process and improved workefficiency. Main research contents are as follows： 1. A FEM model has been developed on basis of base structure of certain functionmaster model checking fixture. It has put forward requirements and principles on buildingFEM model of base structure and has analyzed major problems while modeling, includingstructure simplified, geometrical model sorting, elements selection, welding spot treatment,etc. At last it calculates rigidity and natural frequency of base by applying FEM method.2. DOE analysis method is applied to plating thickness parameter optimization of base.The optimization design is taking thickness of each component of checking fixture base asdesign variable, volume as target function and displacement of key nodes under differentoperation condition as constraint condition. The results show that under the condition thataccuracy requirement isn’t lowered, the optimization scheme has lightened base weight by14.4%.3. Standard process system is developed pointing to FEM analysis of checking fixturebase and size optimization according to corporation’s practical demand. By usingautomatic process system to finish part of CAE analysis, it is helpful to improve workefficiency, reduce manual work and lessen error probability. Finally the correctness andpracticability of HyperMesh CAE process automatic system is illustrated by runningexamples.