| With the development of new energy vehicles in China,the issue of scope is becoming increasingly prominent,while also addressing global energy conservation and emission reduction.Optimizing the structure of aluminum alloy wheels under safe conditions has become an important way to save energy and reduce emissions.As the main load-bearing mechanism and rotating component of automobiles,the weight reduction effect of wheel hubs is approximately 1.3 times that of other non rotating components.This article uses the finite element modeling method to model the fatigue test of wheel hubs,modeling and calculating the maximum equivalent force and fatigue life,minimum number of cycles,and wheel hub optimization under a given load.The main content includes:（1）Establishing a three-dimensional model of the wheel according to the product parameters and actual measurements,establishing a three-dimensional model of the wheel according to the product parameters and actual measurements,and performing simulation calculations of the free and restrained modes of the wheel,and using the DH5922D dynamic signal test system to perform modal tests on the wheel to extract the frequencies and corresponding vibration patterns of the wheel.The error between the free mode experiment and the simulation results is less than±3%,and the suppression mode simulation frequency is within4 times of the experimental frequency,which confirms the accuracy of the wheel model and ensures the accuracy of the subsequent finite element simulation and the prediction of the wheel fatigue life.（2）According to the description of wheel fatigue test according to national standards,a simulation model was established for calculation,and the entire test process was simulated using the multi load step method.The simulation results show that the maximum equivalent stresses in the bending and radial directions of the wheel are 93.04 MPa and 121.96 MPa,respectively,which are less than the allowable stress of the wheel material.The stress concentration zone has been detected,laying a foundation for predicting the fatigue durability of the wheel.Based on the results of finite element modeling of wheels using NCODE software,the minimum number of cycles for wheel fatigue durability was predicted,and the damage pattern was corrected using the cycle coefficient correction method.Therefore,the correction can be applied to the calculation of multi-step fatigue damage.The minimum cycle number of wheel bending fatigue life is 2.89×105 cycles;the minimum cycle number of radial fatigue life is 5.65×106 cycles,which lays the foundation for the subsequent wheel optimization.（3）Based on the results of wheel finite element modeling and fatigue durability prediction,the topology of the wheel structure was optimized to find the optimal distribution of materials in the wheel structure,and the wheel finite element modeling and fatigue durability prediction were calculated.The simulation results indicate that the redesigned wheel mass has decreased by approximately 10.8%,and the maximum wheel stress is lower than the required material stress.The minimum fatigue life cycle for optimizing wheel bending is approximately 1.5×105cycles.The minimum number of cycles for radial fatigue life of wheels is approximately 2×106.This meets the requirements of the minimum number of cycles for radial fatigue life of national truck wheels.（4）The wheel model of topology optimization is bionic optimization.Honeycomb is a typical lightweight and high-strength structure in nature,with dynamic characteristics similar to the typical working stress when the wheels are bent.The wheel position of the vehicle has been redesigned based on the honeycomb structure.The distance from the steel reinforcement to the surface of flange(32,the thickness of the hole wall to reduce the weight of(34,and the aperture of honeycomb spoke(35 were selected as the optimization parameters for biomimetic optimization of wheel response surface analysis.The final result of wheel bending fatigue durability simulation is 1.72×105 times.The minimum number of cycles required by the national standard for bending fatigue durability of truck wheels.Compared with the topology optimization wheels,the final version of the honeycomb bionic wheel has a mass reduction of about 23%,and the mass reduction area is mainly concentrated under the wing.The spider web structure has high strength and elasticity,and can withstand high tensile and torsional forces,with stress situations similar to radial loads on wheels.The position of the wheel beam was redesigned based on the mesh structure,with(41 angle between the steel bars and the mesh beam,(42 distance between the steel bars and the mesh beam,and(43 thickness of the steel bars as design parameters.The mesh wheel was optimized using BP neural network.The final result of wheel bending fatigue durability simulation is 1.25×106times.The minimum number of cycles for radial fatigue life of truck wheels in accordance with national standards.Compared with the topology optimization wheel,the quality of the final version of the honeycomb bionic wheel is reduced by about 26.7%.Comparing the rotational characteristics of three wheels,the biomimetic wheel exhibits improved rotational characteristics at the same speed.Finally,other lightweight and high-strength structures in nature are discussed and the hub is bionically optimized.The maximum stress corresponding to the bionic hub is calculated to be less than the allowable stress of the material. |
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