Truck Frame Forward Design Based On Interval Segmentation Topology Optimization

In the case of worse air quality, people have realized the importance of environmental protection. With the request of energy conservation and emissions reduction from the Government,specially as the main emitters of air pollutants,truck industry firstly to be affected. In the whole system of a car, there are two main ways to reduce the emissions of pollutants currently. One is to promote the performance of engines, but it is not easy to work; Another important way is to reduce the vehicle weight, this is a highly feasible and relatively simple solution. While a car's weight reduced, it is effective capacity, operation stability, fu-el economy and safety will be accordingly promoted. The weight of a frame is the largest in all the assembly of a whole vehicle, so the frame lightweight design is equal to reduce the weight of a truck.The wide lightweight design method is firstly to analyze the performance of the original frame. Then determine the optimal space and remove the redundant weight of a frame according to the result. So its efficiency is not high and it is not fit for lightweight design of new products. Topology optimization can rapidly design new parts under its work requirements. So it can be used as a lightweight method in the concept design phase. But when a model is larger,the result of direct topology calculation is usually mixed. So the topological space should be first divided into several small areas in accordance with the working requirements to confirm the new frame structure as soon as possible.Then the lighter structure could be gotten after using size optimization synthetically.Topology optimization is presented for continuum structure while it is still fit for the situation of discrete unit. Bolt is mainly used to connect bridge and connecting plate in a frame. But the serious force area should be installed with high strength bolts to keep the whole frame stress balance. And the installation areas are generally difficult to be located. Actually topology could be easily used to solve the problem.That the function of a frame is to connect kinds of parts to make it work is important. So lightweight is not equal to reduce weight optionally but the weight is lightest with meeting the true performance in stiffness and strength. So after the frame optimization design there are still typi-cal performance analysis and real vehicle test to make sure the new frame can satisfy working requirement.