Research On Structural Optimization And Forming Process Of Energy Absorbing Box Based On Egg-shaped Structure

During the low-speed collision of the vehicle,the car’s energy absorption box absorbs the energy generated by the collision through its own collapse deformation,and transmits the collision force to the front side member of the vehicle.In protecting the side member of the car,the body structure is complete,Personal safety plays an important role.At present,in the design and research of the shape and structure of automobile energy absorption boxes,regular geometric columns are mainly used.The energy absorption efficiency is slightly lower,the collision force peak is larger,and the mass is larger.Therefore,there are still improvements in energy absorption effect and light weight structure.space.In this subject,the finite element simulation of the egg-shaped energy-absorbing box is performed to achieve the purpose of optimizing and reducing the weight of the energy-absorbing box structure,and researching its forming process to trial-produce the prototype.Based on the principle of bionics,this topic analyzes the zonal contour roundness of the egg-shaped structure,the radial similarity of the generatrix,and the distribution of the egg-shaped coefficient,and establishes the volume equation,surface area equation,and egg-shaped coefficient equation of the egg-shaped structure.The above demonstrates the application feasibility of the egg-shaped structure in the structural design of the energy absorption box.Through finite element simulation analysis,it is concluded that the energy absorption effect of the egg-shaped energy absorption box is the best under the same conditions,followed by the cylindrical energy absorption box,and finally the hexagonal energy absorption box.The egg-shaped energy absorption box is more than the hexagonal prism.The energy absorption effect of the energy absorption box is increased by nearly 37.5%,and the deformation of the force is more regular.This further confirmed the feasibility of the egg-shaped structure design in improving the crashworthiness and energy absorption of the energy absorption box.Based on this,the conceptual design of the egg-shaped structure energy absorption box model is mainly based on the UG modeling and Abaqus nonlinear display dynamics analysis module,and the finite element simulation is used to simulate the deformation dynamics of the conceptual model under the conditions of collision regulations As a result,the corresponding collision force curve graph and energy absorption curve were obtained.The simulation experiment showed that the peak value of the collision force was 21620 N,which was less than the yield stress of the side member,which ensured that the side member of the automobile would not be plastically deformed.The finite element analysis results of the conceptual model show that: the induction groove can guide the collision deformation and reduce the peak of the collision force;the egg-shaped structure is stable in deformation during the collision;the addition of the surface structure hole design can achieve the lightweight without changing the collision of the original structure stability.Based on the orthogonal experiment method,the experimental schemes of the three structural index parameters of the design of the induction slot arrangement of the energy absorption box,the design of the light-weight structural holes,and the selection of the wall thickness were used to obtain an orthogonal experiment table of three factors and three levels.Through the finite element simulation analysis,the influence trends of various factors on the energy absorption effect of the energy absorption box are obtained: as the wall thickness increases,the number of induction grooves,and the number of surface structure holes increase,the specific energy absorption becomes a downward trend;the average collision force and The wall thickness is proportional to the number of surface structure holes,and is inversely proportional to the number of induction grooves.Among them,the wall thickness contrast has the most obvious impact on energy absorption and average collision force.For every 1mm increase in wall thickness,the specific energy absorption decreases by nearly 50%,and the average collision force increases.Nearly 1x.After analyzing the results of comprehensive orthogonal experiments,it can be found that the wall thickness is 1mm,the number of induction grooves is 3 and they are evenly arranged,and the upper and lower ends of the openings are horizontally and evenly open 4 holes,the radius is 4mm,and the middle part is horizontally and evenly horizontally.The optimal structure is 8 holes with a radius of 1.5mm.The modal simulation analysis of the optimal structure of the energy-absorbing box shell was performed by Abaqus software,and the 1-4 order natural frequency and modal shape of the constrained modal shell were obtained to obtain the dynamic characteristics of the shell structure.By analyzing and comparing four common 3D printing methods,laser tailor welding technology,hydroforming technology,hot forming technology,casting technology,and machining technology,the feasibility and advantages and disadvantages of each solution are summarized,and the structure and materials of the egg-shaped energy absorption box are combined.The special characteristics of SLM technology were chosen to realize the manufacture of prototype egg-shaped energy absorption boxes.The finished product of the egg-shaped energy-absorbing box was manufactured using RENISHAW AM250,and the rationality of the structure of the egg-shaped energy-absorbing box was verified through actual production,and the reliability of the forming process was verified.