Structure Lightweight Design Of The Key Part Of The Passenger Car Body Based On The Principle Of Topology Optimization

Now the new energy automotive, energy saving and emission reduction is the future development of automobile industry, much needed fuel or battery, is closely related with the car weight. The weight of the body in the vehicle in the proportion of larger, so the lightweight body directly affects the degree of energy saving and emission reduction of the whole effect.Way to realize the lightweight car body are:the form of spatial topological structure optimization of body, make all kinds of work load and impact load can be effectively transferred; reduced body size or thinning of parts thickness; optimization of appearance, used to reduce the number of strengthening element stiffness; by improving the parts and connection technology to reduce parts the number of forming; with low density materials to replace the high density material. In addition, light weight at the same time, also must meet the body structure strength and stiffness, vibration and noise, collision and energy absorption design standards and regulations, and ensure the technology and economy of.All the quality indicators and ultimately to human feelings as the evaluation index, so lightweight also relates to ergonomics and biomechanics and human physiology, especially dynamic man-machine interface normal running of the vehicle or crash involving methodology.This paper selected the car left front door anti-collision rod as the research object, do statistical research of the current market popular in Europe and America vehicle door anti-collision rod structure type, for different structures in engineering application, the quality of the collision performance and occupant protection were analyzed; the development history of topology optimization, the principle, mathematical model and algorithms used to do in-depth research and development, and to the topology optimization principle as the foundation, carries on the grid division, using the finite element software Hypermesh grid quality check, and combined with the solver OptiStruct to describe the optimization model, the optimization goal setting, structure lightweight obtained bumper design variables and establish constraints the step.This thesis aims to bumper for example, systematic research on the theory of topology optimization in the lightweight design practice, improve the crashworthiness of passenger car, reduce the body quality and fuel consumption.Research methods:through statistical investigation of the structure and material of anti-collision rod at present Europe and Japan and Korea economic models used, respectively, comparison and analysis of the structure properties of different section, on the basis of the three-dimensional software set containing the initial topology geometry model of all the section size, and then into the finite element analysis software HyperWorks for grid the division and check, then the material properties, design parameter set according to the design condition, create load set, constraint boundary conditions, applied force, create loads, according to the design variables, the optimization goal definition of topological optimization is defined to optimize response (volume fraction) and the objective function (minimum), after the completion of the above work in Hypermesh, and then imported to the structure optimization and topology optimization arithmetic can meet the design requirements of the topological structure of software OptiStruct, and the topology optimization results into3D software to two times of the design, more suitable for practical use and layout structure.Results and conclusion:the theory of topology optimization to obtain the quality is light, safe and reliable open type M shaped anticollision beam structure better collision energy absorption, provides new ideas and methods for structure lightweight body structure parts of the design in the future.The innovation of this paper lies in:the theory of topology optimization is applied to the structural lightweight design, comparison and analysis of the impact of different shapes, different materials, different process on the impact performance. Using a combination of three-dimensional software, software of finite element analysis and structural optimization software development, shorten the design cycle, improve design efficiency.