Research On The Lightweighting Of A Light Bus’ S Body In White

The vigorous development of the automobile industry has brought convenience to people’s lives,but it has also produced three major problems: energy consumption,exhaust emissions and driving safety.Automobile lightweight is the most direct and effective means among many energy-saving and emission reduction methods,and is an important subject and direction for the automobile manufacturing industry to study for a long time.As an important part of the whole vehicle,the reasonable lightweight design of the body-in-white can not only achieve the goal of weight reduction,but also improve the safety performance of the whole vehicle.At present,it is mainly through the use of structural optimization design methods,the application of new lightweight materials and the use of advanced forming technology to realize the lightweight of the car body in white.In this paper,the body-in-white of a light bus is taken as the research object.Based on the geometric model of the light bus,the finite element model of the whole vehicle is built using HyperWorks preprocessing software,and the rollover simulation model of the light bus is built according to the laws and regulations.The accuracy and effectiveness of the simulation model are verified by comparing with the rollover test results of the real vehicle,and the stiffness and modal performance of the light-bus body-in-white are analyzed.After that,some key components of BIW are selected for mass,stiffness and modal sensitivity analysis.According to the results of sensitivity analysis,the components that need to be optimized are selected and the corresponding lightweight scheme is formulated.Replace the light material 6061 aluminum alloy with the parts with high quality sensitivity and structural performance sensitivity,reduce the size of the parts with high quality sensitivity and low structural performance sensitivity,increase the size of the parts with low quality sensitivity and high structural performance sensitivity,and do not deal with the parts with low quality sensitivity and structural performance sensitivity.Then establish a mathematical model for size optimization,set relevant parameters as required,and submit it to the OptiStruct module for solution.After 7 iterations of calculation,the results converge to obtain the lightweight results of the light bus body in white.Then carry out rollover simulation test on the optimized vehicle to verify its rollover safety performance,and carry out structural performance analysis on the lightweight body-in-white,and the test results meet the standard requirements.Under the conditions of ensuring the structural performance of the white body of the light bus and the safety performance of the vehicle’s rollover,a weight reduction of 18.6 kg was achieved,achieving the goal of energy conservation and emission reduction.