Lightweight-oriented Topology Optimization Research On Holder Part Of Commercial Vehicles

As the basic component of automobile, auto parts is either the basis of gross vehiclemass, or the important foundation of the research and development of auto product. Thepromotion of a lightweight vehicle still lies in the promotion of lightweight auto parts.Regarded as an effective way of auto lightweight technology, structural and topologicaloptimization design has currently become the most potential priority research area in additionto the application of new material and new process in lightweight technology. With theapplication of evolutionary structural optimization (ESO) and based on the realization ofANSYS platform, this article probes into the topological optimization design of holder part ofcommercial vehicle. The details are as follows:(1) It overviews the development and domestic and foreign research status of lightweightauto parts and structural topology optimization methods, and summarizes the topologicaloptimization method of vehicle holder parts. Proposed the advantages of applying ESO onholder part’s topology optimization, and obtained the overall research idea.(2) On the basis of structural optimization designing concepts and the mathematicalmodel, elaborates the basic theory, establishment of mathematical model based on stress andstiffness and calculation method of sensitivity. A brief analysis is conducting on the numericalinstability during the topology optimization process when applying the ESO method.(3) It draws a conclusion to the structure and stressing feature of holder part ofcommercial vehicle. On this basis, this article adopts multi-objective optimization design toestablish a mathematical model, which is based on the multiple-objective topologicaloptimization of ESO method. Besides, it introduces the condition of convergence of stress bytaking the holder of certain spring as an example. Based on the secondary development language APDL, this article has realized the2D and3D numerical examples. Through theexamples, it provides that this method is rational and effective, besides, this article gives theselection principle of mapped meshing method and parameter value.(4) Based on the topological optimization of steering gear holder of certain type ofcommercial vehicle, and according to the enterprise requirement to improve the steeringcapacity, the static analysis result of the steering gear holder under the current truck loadingcondition and limited condition fail to cater to the requirement. By establishing the maximumoptimization area of holder, the method of multi-objective topological optimization design,which is based on ESO, has obtained the topological structure of limited condition. Inaddition, manufacturability improvement, which is based on the process knowledge ofinvestment casting, is conducted on the topological structure obtained from the steps above.Finally, the lightweight model of steering gear is obtained. The results show that: the steeringgear holder after optimization meets the requirement of above the safety factor of1.5.Meanwhile, it has realized the weight reduction of10.66%. This method is of certain guidingsignificance to the engineering optimization design of holder part of commercial vehicle.