CN112016160A - Design and optimization method for side impact resistance of automotive aluminum alloy thin-wall beam - Google Patents
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Abstract
The invention provides a method for designing and optimizing side impact resistance of an aluminum alloy thin-wall beam for a vehicle, which comprises the following steps: defining structural characteristics and material selection of the aluminum alloy thin-wall beam; designing an internal reinforcing structure of the aluminum alloy thin-wall beam; finite element modeling and test verification; defining a crashworthiness design index; determining the topological form of the section of the thin-wall beam; constructing a thin-wall beam sample cell through wall thickness combination; constructing a display mathematical relation between the wall thickness of the thin-wall beam and each crashworthiness design index; defining and solving an approximate multi-objective optimization problem; generating a supplementary sample point and adding the supplementary sample point into a thin-wall beam sample pool database; judging whether the optimization convergence criterion is met, if so, finishing the optimization iteration; if not, updating the proxy model based on the sample point database after adding points, and optimizing iteration until the convergence requirement is met. The invention has the beneficial effects that: the lateral crashworthiness design of the light aluminum alloy thin-wall beam for the vehicle is effectively realized, the trial-production turn number and the crashworthiness test number of thin-wall beam samples are reduced, and the research and development period is shortened.
Description
Technical Field
The invention belongs to the technical field of vehicle thin-wall beam performance design, and particularly relates to a side impact collision resistance design and optimization method for a vehicle aluminum alloy thin-wall beam.
Background
The density of the aluminum alloy is about 1/3 of steel, and the aluminum alloy has good mechanical property and excellent machining property, so the aluminum alloy becomes an important material for reducing the weight of an automobile. Structural elements such as aluminum alloy thin-wall beams, rods and pipes are increasingly applied to vehicle body structures in the past decades, particularly to the design of new energy vehicle body structures with higher requirements on light weight levels.
The automobile collision safety problem is one of the most troublesome public health problems facing the current society, and the automobile can not sacrifice the collision safety while being light. Aiming at the safety requirement of the lightweight passenger vehicle under the collision working condition, the collision resistance of the aluminum alloy hollow thin-wall structure, the reinforced thin-wall structure and the filling thin-wall structure under various impact loads in the axial direction and the lateral direction (transverse direction) is widely researched.
In the passenger car industry, compared with collision working conditions such as direct collision, rear collision and the like of passenger cars, the side turning of the passenger car has greater danger to public life and property, and the caused consequences are more serious. Under the side-turning working condition, the lateral impact resistance of the structures such as a gantry frame, an upright post, a window cross beam and the like formed by the thin-wall beams in the passenger car body has the greatest influence on the safety of the passenger car body, so that the development of the lateral impact resistance design and the optimization research of the novel aluminum alloy thin-wall beams for the car has important guiding significance on the design of the car body structure of the light-weight new-energy passenger car.
Disclosure of Invention
In view of the above, the present invention aims to provide a design and optimization method for side impact resistance of an aluminum alloy thin-wall beam for a vehicle, so as to solve the above-mentioned disadvantages.
In order to achieve the purpose, the technical scheme of the invention is realized as follows:
a method for designing and optimizing side impact resistance of an aluminum alloy thin-wall beam for a vehicle comprises the following steps:
A. defining structural characteristics and material selection of the aluminum alloy thin-wall beam;
B. designing an internal reinforcing structure of the aluminum alloy thin-wall beam;
C. finite element modeling and test verification;
D. defining a crashworthiness design index;
E. determining the topological form of the section of the thin-wall beam;
F. constructing a thin-wall beam sample cell through wall thickness combination;
G. constructing a display mathematical relation between the wall thickness of the thin-wall beam and each crashworthiness design index based on the proxy model;
H. defining and solving an approximate multi-objective optimization problem;
I. generating a supplementary sample point based on a sample adding criterion and adding the supplementary sample point into a thin-wall beam sample pool database;
J. judging whether the optimization convergence criterion is met, if so, finishing the optimization iteration; if not, updating the proxy model based on the sample point database after adding points, and optimizing iteration until the convergence requirement is met.
Furthermore, in the step A, a combination form of an outer layer regular geometric shape and an inner complex reinforcing structure is defined, a common aluminum alloy grade of the bearing structural member is selected, and a material stress-strain curve is obtained through uniaxial tension.
Further, in the step B, the internal reinforcing structure of the thin-wall beam is defined as a basic geometric shape or a reinforcing rib.
Further, in the step C, a side impact finite element model of each thin-wall beam is established, and the reliability of modeling is verified under a quasi-static working condition by performing three-point bending simulation and test comparison on the basic aluminum alloy thin-wall beam without the internal reinforcing structure.
Further, in the step D, defining crashworthiness design indexes based on the bending resistance of the thin-wall beam and the stability of the collision process, wherein the crashworthiness design indexes comprise the structural total specific energy absorption SEA of the thin-wall beamtotalMaximum collision force CFmaxAverage collision force CFavgAnd the coefficient of impact force CFE,
wherein F (x) is the impact force of the punch, the impact stroke and the mass of the thin-wall beam;
wherein CF (l) is the acting force of the punch when the collision stroke is lmm;
and furthermore, in the step E, various impact resistance indexes of the aluminum alloy thin-wall beam under different design schemes are analyzed through side impact simulation comparison, and the thin-wall beam section with the optimal comprehensive performance is selected as a final topological form.
And further, in the step F, the thin-wall beams under the wall thickness combination of each part are extracted as sample points based on a test design method, and corresponding crashworthiness design indexes are obtained through side impact simulation.
Further, in the step H, the wall thickness of each part of the thin-wall beam is used as a design variable, the design index of the collision resistance of the related energy absorption class and the safety class is promoted to be used as an optimization target, a mathematical model of a proxy model optimization problem is constructed, the proxy model optimization problem is solved by adopting an advanced optimization algorithm to obtain the pareto front, and a thin-wall beam wall thickness matching scheme is selected.
Compared with the prior art, the design and optimization method for the side impact resistance of the automobile aluminum alloy thin-wall beam has the following advantages:
according to the design and optimization method for the side impact resistance of the automobile aluminum alloy thin-wall beam, disclosed by the invention, the design of the side impact resistance of the automobile light aluminum alloy thin-wall beam is effectively realized through high-efficiency and high-precision simulation and optimization, the trial-manufacture wheel number of thin-wall beam samples and the impact resistance test frequency are reduced, the capital and time cost is saved, and the research and development period is shortened; the requirement on engineering experience of designers is low, the human resource cost is saved to a certain extent, and the research and development cost is reduced.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an embodiment of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 is a flow chart of a method for designing and optimizing side impact resistance of an aluminum alloy thin-wall beam for a vehicle according to an embodiment of the invention;
FIG. 2 is a schematic structural diagram of a thin-walled beam according to an embodiment of the present invention with a basic geometry inside;
FIG. 3 is a schematic structural view of a thin-wall beam according to an embodiment of the present invention, in which reinforcing ribs are disposed inside the thin-wall beam;
FIG. 4 is a schematic view of a side impact condition of a thin-wall beam according to an embodiment of the present invention;
FIG. 5 is a side impact finite element model of a thin wall beam according to an embodiment of the present invention;
fig. 6 is a flow of implementing the adaptive point-filling method.
Detailed Description
It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict.
The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
As shown in fig. 1, a method for designing and optimizing side impact resistance of an aluminum alloy thin-wall beam for a vehicle comprises the following steps:
A. defining structural characteristics and material selection of the aluminum alloy thin-wall beam;
B. designing an internal reinforcing structure of the aluminum alloy thin-wall beam;
C. finite element modeling and test verification;
D. defining a crashworthiness design index;
E. determining the topological form of the section of the thin-wall beam;
F. constructing a thin-wall beam sample cell through wall thickness combination;
G. constructing a display mathematical relation between the wall thickness of the thin-wall beam and each crashworthiness design index based on the proxy model;
H. defining and solving an approximate multi-objective optimization problem;
I. generating a supplementary sample point based on a sample adding criterion and adding the supplementary sample point into a thin-wall beam sample pool database;
J. judging whether the optimization convergence criterion is met, if so, finishing the optimization iteration; if not, updating the proxy model based on the sample point database after adding points, and optimizing iteration until the convergence requirement is met.
In the step A, considering the influence of a forming process and a novel connecting process, defining the combination form of an outer layer regular geometric shape and an inner complex reinforcing structure, selecting a common aluminum alloy mark of a bearing structural member, and obtaining a material stress-strain curve through uniaxial tension. In the embodiment, based on the process of extrusion forming, adhesive bonding and the like of a doorframe, an upright post, a window beam and the like of an all-aluminum body framework of a certain lightweight pure electric passenger vehicle, a thin-wall beam structural element is defined as a section geometric form of an outer-layer semicircular surface and an inner complex reinforcing structure, a 6060-T66 mark in 6XXX series aluminum alloy is selected, and the density, the Poisson ratio and a uniaxial tensile stress-strain curve of the material are measured to be used as simulation input.
In the step B, two types of thin-wall beam internal reinforcing structures are defined, as shown in fig. 2, one type is a basic geometric shape, and the method includes: circular, elliptical, rectangular, triangular, and trapezoidal; as shown in fig. 3, the other type is a reinforcing bar comprising: horizontal and vertical two directions, each 1 ~ 3 strengthening ribs of every direction.
As shown in fig. 4 and 5, in the step C, a side impact finite element model of each thin-wall beam is established, and the reliability of modeling is verified under a quasi-static working condition by performing three-point bending simulation and test comparison on the basic aluminum alloy thin-wall beam without the internal reinforcing structure. In the embodiment, a Hyperworks module based on Hyperworks software establishes a side impact finite element model and a simulation working condition of each thin-wall beam, Ls-Dyna is used as a solver to perform three-point bending simulation and test on the basic aluminum alloy thin-wall beam without an internal reinforcing structure, and the reliability of modeling is verified under a quasi-static working condition by comparing a force-displacement curve of a punch.
In the step D, defining crashworthiness design indexes based on the bending resistance of the thin-wall beam and the stability of the collision process, wherein the crashworthiness design indexes comprise the structural total specific energy absorption SEA of the thin-wall beamtotalMaximum collision force CFmaxAverage collision force CFavgAnd the coefficient of impact force CFE,
wherein F (x) is the impact force of the punch, the impact stroke and the mass of the thin-wall beam;
wherein CF (l) is the acting force of the punch when the collision stroke is lmm;
and E, analyzing various impact resistance indexes of the aluminum alloy thin-wall beam under different design schemes, namely the total specific energy absorption, the maximum impact force, the average impact force and the impact force coefficient of the aluminum alloy thin-wall beam series through side impact simulation contrast, considering the bending resistance and the stability of the impact process of the thin-wall beam, and selecting the thin-wall beam section with the optimal comprehensive performance as a final topological form.
And in the step F, the thin-wall beam under the wall thickness combination of each part is extracted as a sample point based on a test design method, and a corresponding crashworthiness design index is obtained through side impact simulation. In the embodiment, the DOE module of HyperStudy software is provided with the variation range of design variables and the number of sample points, a Latin hypercube test design method is selected to extract the sample points, and the sample point data is stored in a sample pool database; and introducing the thin-wall beam model sample into Ls-Dyna for solving and calculating, and performing post-processing through Hyperview software to obtain the total specific energy absorption and the maximum impact force of the structure corresponding to the thin-wall beam sample.
And in the step G, an RBF proxy model is constructed in a Fit module of Hyperstudy software according to the sample points in the thin-wall beam sample pool database and the corresponding structural total specific energy absorption value and the maximum impact simulation value.
And in the step H, the wall thickness of each part of the thin-wall beam is used as a design variable, the design indexes of related energy absorption and safety collision resistance are improved and used as optimization targets, a proxy model optimization problem mathematical model is constructed, an advanced optimization algorithm is adopted to solve the proxy model optimization problem to obtain the pareto front, and a thin-wall beam wall thickness matching scheme is selected. In the embodiment, in an Optimization module of HyperStudy software, a multi-objective Optimization problem of a proxy model is defined by taking the minimized maximum collision force and the maximized structural total specific absorption energy as Optimization targets, an MOGA Optimization algorithm is adopted to solve the Optimization problem to obtain a pareto optimal solution set of the wall thickness of a thin-wall beam, an inflection point in the front edge of the pareto is extracted based on the following formula to serve as a design scheme of the thin-wall beam,
where N is the number of target equations, fcτD is the euclidean distance from the "inflection point" to the "ideal point" for the corresponding τ -th objective function value in the C-th pareto optimal solution.
In the step I, as shown in FIG. 6, complementary sample points are generated, thin-wall beam models corresponding to the complementary points are guided into Ls-Dyna to be solved and calculated, structural overall specific absorption energy and maximum impact force corresponding to the samples are obtained through aftertreatment by Hyperview software, and the structural overall specific absorption energy and the maximum impact force are added into a sample pool database.
In the step J, after a new sample point is generated and the RBF model is updated, a new round of multi-target optimization is executed, and when the pareto front obtained by the optimization and the optimization of the last time meet the following formula, the pareto front is considered to be not changed greatly after the optimization is performed twice, and the algorithm is converged; otherwise, returning to the step I for iterative optimization until the condition algorithm convergence is met.
In the formula, mean represents an average value, R is an approximate value of a crashworthiness design target, i represents the ith design target, EP (last) represents a pareto front edge end point obtained by last optimization, EP (current) represents a pareto front edge end point obtained by current optimization, POF (last) represents a pareto front edge obtained by last optimization, POF (current) represents a pareto front edge obtained by current optimization, the default value of eta is 5%, and a designer can adjust the design according to actual conditions.
The invention establishes a design and optimization method for side collision resistance of the aluminum alloy thin-wall beam for the vehicle based on collision simulation and surrogate model optimization technology, improves the comprehensive side collision resistance of the thin-wall beam by reasonably matching the wall thickness of each part after determining the cross section form of the beam, and has important significance for the development of passive safety simulation technology of the vehicle.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (9)
1. A method for designing and optimizing side impact resistance of an aluminum alloy thin-wall beam for a vehicle is characterized by comprising the following steps:
A. defining structural characteristics and material selection of the aluminum alloy thin-wall beam;
B. designing an internal reinforcing structure of the aluminum alloy thin-wall beam;
C. finite element modeling and test verification;
D. defining a crashworthiness design index;
E. determining the topological form of the section of the thin-wall beam;
F. constructing a thin-wall beam sample cell through wall thickness combination;
G. constructing a display mathematical relation between the wall thickness of the thin-wall beam and each crashworthiness design index based on the proxy model;
H. defining and solving an approximate multi-objective optimization problem;
I. generating a supplementary sample point based on a sample adding criterion and adding the supplementary sample point into a thin-wall beam sample pool database;
J. judging whether the optimization convergence criterion is met, if so, finishing the optimization iteration; if not, updating the proxy model based on the sample point database after adding points, and optimizing iteration until the convergence requirement is met.
2. The method for designing and optimizing the side impact resistance of the automotive aluminum alloy thin-walled beam according to claim 1, wherein the method comprises the following steps: in the step A, a combination form of an outer layer regular geometric shape and an inner complex reinforcing structure is defined, a common aluminum alloy mark of a bearing structural member is selected, and a material stress-strain curve is obtained through uniaxial tension.
3. The method for designing and optimizing the side impact resistance of the automotive aluminum alloy thin-walled beam according to claim 1, wherein the method comprises the following steps: and in the step B, defining the internal reinforcing structure of the thin-wall beam as a basic geometric shape or a reinforcing rib.
4. The method for designing and optimizing the side impact resistance of the automotive aluminum alloy thin-walled beam according to claim 1, wherein the method comprises the following steps: and C, establishing a side impact finite element model of each thin-wall beam, and verifying the reliability of modeling under a quasi-static working condition by performing three-point bending simulation and test comparison on the basic aluminum alloy thin-wall beam without the internal reinforcing structure.
5. The method for designing and optimizing the side impact resistance of the automotive aluminum alloy thin-walled beam according to claim 1, wherein the method comprises the following steps: in the step D, defining crashworthiness design indexes based on the bending resistance of the thin-wall beam and the stability of the collision process, wherein the crashworthiness design indexes comprise the structural total specific energy absorption SEA of the thin-wall beamtotalMaximum collision force CFmaxAverage collision force CFavgAnd the coefficient of impact force CFE,
wherein F (x) is the impact force of the punch, the impact stroke and the mass of the thin-wall beam;
wherein CF (l) is the acting force of the punch when the collision stroke is lmm;
6. the method for designing and optimizing the side impact resistance of the automotive aluminum alloy thin-walled beam according to claim 1, wherein the method comprises the following steps: and E, analyzing various impact resistance indexes of the aluminum alloy thin-wall beam under different design schemes through side impact simulation comparison, and selecting the thin-wall beam section with the optimal comprehensive performance as a final topological form.
7. The method for designing and optimizing the side impact resistance of the automotive aluminum alloy thin-walled beam according to claim 1, wherein the method comprises the following steps: and in the step F, the thin-wall beam under the wall thickness combination of each part is extracted as a sample point based on a test design method, and a corresponding crashworthiness design index is obtained through side impact simulation.
8. The method for designing and optimizing the side impact resistance of the automotive aluminum alloy thin-walled beam according to claim 1, wherein the method comprises the following steps: and in the step H, the wall thickness of each part of the thin-wall beam is used as a design variable, the design indexes of related energy absorption and safety collision resistance are improved and used as optimization targets, a proxy model optimization problem mathematical model is constructed, an advanced optimization algorithm is adopted to solve the proxy model optimization problem to obtain the pareto front, and a thin-wall beam wall thickness matching scheme is selected.
9. The method for designing and optimizing the side impact resistance of the automotive aluminum alloy thin-walled beam according to claim 1, wherein the method comprises the following steps: in the step J, after a new sample point is generated and the RBF model is updated, a new round of multi-target optimization is executed, and when the pareto front obtained by the optimization and the optimization of the last time meet the following formula, the pareto front is considered to be not changed greatly after the optimization is performed twice, and the algorithm is converged; otherwise, returning to the step I for iterative optimization until the condition algorithm convergence is met,
in the formula, mean represents an average value, R is an approximate value of a crashworthiness design target, i represents the ith design target, EP (last) represents the pareto front edge end point obtained by the last optimization, EP (current) represents the pareto front edge end point obtained by the current optimization, POF (last) represents the pareto front edge obtained by the last optimization, POF (current) represents the pareto front edge obtained by the current optimization, and the default value of eta is 5%.
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