Study On Crashworthiness Optimization Design And Stamping Process Of High Strength Steel Anti-Collision Beam

Due to the rapid growth of the national economy,car ownership is growing rapidly,the supply and demand relationship of various resources is tense,which makes the rapid development of new energy vehicles.However,with the increase of the number of cars,traffic congestion,collision accidents and other problems,safety is an important index of automobile design.From the consideration of environmental protection and resource saving,lightweight is also an important concern of automobile development.Taking the front bumper of a new energy vehicle as the research object,the lightweight and crashworthiness optimization design of the anti-collision beam was carried out,and the stamping forming process and process parameter optimization of the anti-collision beam were systematically studied.Firstly,based on China’s low-speed collision regulations,a frontal collision study of the anti-collision beam was conducted.Abaqus was used to simulate the collision process of the initial anti-collision beam system.The evaluation indicators were energy absorption,intrusion amount,and peak collision force.The crashworthiness of the initial anti-collision beam model was analyzed,and based on the collision results,optimized anti-collision beam parameters were found.Secondly,while meeting collision safety requirements,the initial anti-collision beam is lightweight in material and replaced with high-strength steel instead of ordinary steel.The cross section parameters of the anti-collision beam were multi-objective optimized.With the mass and maximum intrusion as the optimization objectives,the optimal Latin hypercube sampling method was used to obtain the design variables and response values and establish an approximate RBF surrogate model.The multi-objective optimization of the variable cross section parameters of the anti-collision beam was carried out combined with the NSGA-II optimization algorithm to obtain the optimal combination of cross section parameters.Compared to the initial anti-collision beam,the mass of the multi-objective optimization anti-collision beam decreased by 20.7%,the maximum intrusion amount decreased by 17.99%,the energy absorption increased by 0.41%,and the peak collision force decreased by 8.54%.While meeting the lightweight requirements,various crashworthiness indicators have also been improved.Finally,the stamping process and parameters of the anti-collision beam were optimized.Including the design of the supplementary surface,the direction of stamping,the size of sheet material and the form of drawing bar,the finite element model of the anti-collision beam was established.The effects of blank holding force,friction coefficient,die clearance and stamping speed on the thinning rate and springback of the anti-collision beam were analyzed.Orthogonal experiments were carried out to select the best combination of process parameters.After the simulation calculation,the springback is still large,and the springback compensation was carried out on the anti-collision beam mold.After four iterations of compensation,the maximum springback of the anti-collision beam was reduced to 0.56 mm.The actual stamping test was conducted on the compensated mold surface,and a collision beam component with good forming results was obtained.The actual maximum springback value was 0.61 mm,meeting the rebound requirements of the component.The error between the actual rebound value and the simulated rebound data was 8.9%,proving the feasibility and accuracy of this finite element simulation analysis.