CN112622795B - Head-on collision resistant vehicle structure and manufacturing method - Google Patents

Head-on collision resistant vehicle structure and manufacturing method Download PDF

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Publication number
CN112622795B
CN112622795B CN202011582416.0A CN202011582416A CN112622795B CN 112622795 B CN112622795 B CN 112622795B CN 202011582416 A CN202011582416 A CN 202011582416A CN 112622795 B CN112622795 B CN 112622795B
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connecting piece
extrusion
collision
die
aluminum alloy
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CN112622795A (en
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姜潮
韩旭
雷飞
黄启华
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Hunan University
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Hunan University
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/18—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects characterised by the cross-section; Means within the bumper to absorb impact
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/24—Arrangements for mounting bumpers on vehicles
    • B60R19/26—Arrangements for mounting bumpers on vehicles comprising yieldable mounting means
    • B60R19/34—Arrangements for mounting bumpers on vehicles comprising yieldable mounting means destroyed upon impact, e.g. one-shot type
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D21/00—Understructures, i.e. chassis frame on which a vehicle body may be mounted
    • B62D21/02—Understructures, i.e. chassis frame on which a vehicle body may be mounted comprising longitudinally or transversely arranged frame members
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/20—Floors or bottom sub-units
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/18—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects characterised by the cross-section; Means within the bumper to absorb impact
    • B60R2019/1806—Structural beams therefor, e.g. shock-absorbing
    • B60R2019/1813—Structural beams therefor, e.g. shock-absorbing made of metal
    • B60R2019/182—Structural beams therefor, e.g. shock-absorbing made of metal of light metal, e.g. extruded

Abstract

The invention relates to a vehicle structure resisting head-on collision and a manufacturing method thereof, aiming at the vehicle structure of the invention, the vehicle structure comprises a front collision-proof beam (1); an energy absorption box (2); a front side member (3); a front connection (4); a firewall cross beam (5) and a threshold beam (6); a rear connector (7); a side wall frame (8) and a bottom plate rear cross beam (9); the above components form a transverse closed loop and a longitudinal closed frame. The manufacturing method comprises the following steps: s1: manufacturing the energy absorption box, the front longitudinal beam, the firewall cross beam, the threshold beam and the side frame by adopting an extrusion molding process; manufacturing a front anti-collision beam and a side frame by adopting an extrusion stretch bending forming process; manufacturing a front connecting piece and a rear connecting piece by adopting a casting forming process; s2: the assembly of the vehicle body is performed using the components formed in step S1. The invention can reduce the number and weight of vehicle parts and can realize the improvement of safety performance in the frontal collision.

Description

Head-on collision resistant vehicle structure and manufacturing method
Technical Field
The present invention relates to the field of design and crash safety, and more particularly to a head-on collision resistant vehicle structure.
Background
In the front collision safety design of the automobile, key structures such as a front anti-collision cross beam, an energy absorption box and a front longitudinal beam of an automobile body are main energy absorption parts for front collision, and more than 50% of collision kinetic energy can be absorbed through the crumpling deformation of the structures, so that the impact on a passenger compartment is effectively reduced, and the injury of traffic accidents to people is reduced. In the front 100% rigid wall collision, the energy absorption structure at the front end of the vehicle body is completely overlapped with the barrier, and the energy absorption structures at two sides of the vehicle body are basically under forward axial compression, so that the maximum energy absorption effect can be exerted.
The harsh crash test conditions present significant challenges for vehicle body structure safety design, especially where lightweight design is a concern. In order to reduce the injury of passengers, improve the safety performance of an automobile product in frontal collision, meet the requirement of lightweight design, simplify processing and save cost, the key structure at the front end of the automobile body needs to be subjected to targeted and systematic optimization design.
Disclosure of Invention
The invention aims to provide a vehicle structure for resisting head-on collision, which can reduce the number and weight of vehicle parts, improve the safety performance in the head-on collision, ensure the head-on collision performance, simplify the design, reduce the parts and the processing process flow and meet the requirement of light weight at the same time with lighter weight and less cost under the limited arrangement space of an automobile.
Another object of the present invention is to provide a method of manufacturing the vehicle structure described above, which enables the structure described above to be achieved.
The vehicle structure resisting direct collision comprises an anti-collision beam positioned at the front end of a vehicle body; the energy absorption boxes are arranged at two ends of the back of the anti-collision beam; the front longitudinal beam is arranged at the back of the energy absorption box; the front connecting piece is arranged at the tail end of the front longitudinal beam; the firewall beam is arranged between the two front connecting pieces, and the threshold beam is arranged at the rear end of each front connecting piece; the rear connecting piece is arranged at the rear end of the threshold beam; the side frame is arranged at the top of the front connecting piece and the top of the rear connecting piece, and the bottom plate rear cross beam is arranged between the two rear connecting pieces; the vehicle body forms a transverse closed loop on the horizontal plane, and the transverse closed loop is formed by a front anti-collision beam, an energy absorption box, a front longitudinal beam and a firewall cross beam; the vehicle body forms a longitudinal closed frame surrounded by a front connecting piece, a threshold beam, a rear connecting piece and a side frame on a longitudinal plane.
Because the front connecting piece and the rear connecting piece are used as connecting nodes to form a vehicle structure, the number and the weight of vehicle parts can be reduced, too many connecting accessories such as bolts and the like do not need to be used, a plurality of welding processes can be saved, because a transverse closed loop on a horizontal plane and a longitudinal closed frame on a longitudinal plane are formed, the safety performance in the frontal collision can be improved, the stress conduction is convenient, the collision or impact load generated by the collision is transmitted to the longitudinal closed frame from the transverse closed loop, the influence of the collision on the transverse closed loop is reduced, the safety of the front part of a vehicle body is ensured, the transverse closed loop and the longitudinal closed frame of the vehicle body combined structure share one front connecting piece, the installation is convenient, the force transmission path can be reduced, the transmission piece of the force between the transverse closed loop and the longitudinal closed frame can be prevented from being broken, the frontal collision performance of the vehicle is influenced, in addition, due to the existence of the energy absorption box, the energy absorption effect of the transverse closed-loop structure is better than that of the longitudinal closed frame, part of impact energy can be reduced, and the rigidity of the longitudinal closed frame is higher, so that the integrity of a vehicle body can be ensured.
As a further improvement of the vehicle structure, the front connecting piece is of a cavity structure and is provided with a front end opening for installing a front longitudinal beam; installing a side opening of a firewall beam; mounting a rear end opening of the threshold beam; the rear connecting piece is also of a cavity structure and is provided with a front opening for mounting the threshold beam; installing a top opening at the rear end part of the side frame; the side part of the rear cross beam of the mounting bottom plate is opened.
The front connecting piece and the rear connecting piece are both in cavity structures, and a plurality of openings are arranged, so that other vehicle body force transmission parts can be conveniently installed, and a transverse closed loop and a longitudinal closed frame can be formed.
As a further improvement of the vehicle structure, the bottom surface of the front connecting piece is also provided with a front subframe mounting hole for mounting a front subframe and a front floor mounting surface, the upper surface of the front connecting piece is also provided with a fire wall clapboard overlapping edge, the upper surface of the front part of the rear connecting piece is also provided with a rear floor mounting surface, the upper surface of the rear part is also provided with a trunk floor mounting surface and an overlapping edge for connecting a rear suspension damping structure, and the inner side surface of the rear connecting piece is also provided with a boss, a tubular supporting column and a plurality of transverse and longitudinal crisscross reinforcing rib structures.
The front connecting piece and the rear connecting piece can be used as connecting nodes of other parts of the vehicle, and are provided with bosses, tubular supporting columns and a plurality of transverse and longitudinal crossed reinforcing rib structures to strengthen the connecting nodes, so that the strength and the rigidity of the nodes are ensured, and a transverse closed loop and a longitudinal closed frame are stable.
As a further improvement of the vehicle structure, the energy absorption box, the front longitudinal beam, the firewall cross beam and the threshold beam are formed by extrusion of aluminum profiles; the front anti-collision beam and the side frame are formed by extrusion, stretch bending and molding; the front connecting piece and the rear connecting piece are formed by casting aluminum alloy.
The aluminium alloy extrusion shaping or extrusion stretch-bending shaping wholeness is good, and part self is difficult for scattering the frame, is favorable to the conduction of power, and the intensity and the rigidity of connected node can be guaranteed in aluminium alloy casting shaping, and preceding connecting piece and back connecting piece are as the connected node of a plurality of parts, and strong node is guaranteed in the casting shaping, can improve the integrality of automobile body, even if receive the striking back, also are difficult for scattering the frame.
The manufacturing method specifically comprises the following steps:
s1: manufacturing the energy absorption box, the front longitudinal beam, the firewall cross beam, the threshold beam and the side frame by adopting an extrusion molding process; manufacturing a front anti-collision beam and a side frame by adopting an extrusion stretch bending forming process; manufacturing a front connecting piece and a rear connecting piece by adopting a casting forming process;
s2: the assembly of the vehicle body is performed using the components formed in step S1.
As a further improvement of the manufacturing method of the present invention, in step S1, the extrusion molding process includes the steps of:
(1) preparing a corresponding extrusion die according to the cross section shape of a part to be extruded, and fastening the extrusion die on a port of extrusion equipment;
(2) softening the material, heating the aluminum alloy ingot to 380-440 ℃, and performing laser cutting treatment on the aluminum material according to the required size to prepare a blank;
(3) putting the manufactured blank into the bottom of an extrusion die, enabling an extrusion device in extrusion equipment to advance to the extrusion die at a basically constant extrusion speed, extruding the aluminum alloy cast ingot, and completely extruding the aluminum alloy cast ingot from a die hole of the extrusion die to form an extrusion piece;
(4) tempering the extruded aluminum alloy section, preserving heat, and stretching and straightening the tempered aluminum alloy section to obtain a required part;
the steps are applicable to the energy-absorbing box, the front longitudinal beam, prevent hot wall crossbeam, threshold roof beam, bottom plate rear beam, have the radian to two whole front anticollision roof beam and side wall frame, need stretch bending just can final fashioned part, still need carry on following step:
(5) next to the step (4), the aluminum alloy profile after stretching and straightening is parked for a certain time, the temperature is reduced to 100 ℃ after tempering, bending is carried out, the front anti-collision beam 1 is formed by one-time stretch bending, the side wall frame 8 needs to be subjected to the left and right stretch bending twice respectively for 4 times in total, the middle of the side wall frame 8 is fixed, the left side is firstly subjected to stretch bending, the bending angle is not more than 30 degrees, the second bending angle is not more than 60 degrees, the first bending angle on the right side is not more than 60 degrees, and the second bending angle is not more than 30 degrees;
(6) carrying out artificial heat treatment on the bent aluminum alloy section at the temperature of about 180 ℃ to ensure that the part has enough yield strength and tensile strength after stretch bending
As a further improvement of the manufacturing method of the present invention, in step S1, the front connecting member 4 and the rear connecting member 7 are formed by casting aluminum alloy, and the casting process is an oxygen-filling die-casting method, which includes the following specific steps:
I. preheating a mould at 200 ℃, and putting the smelted material into the mould;
II, closing the die to close the die to form a cavity and a pouring gate, injecting dry oxygen into an injection chamber and the cavity of the die-casting die through the gas injection hole to replace air and other gases in the cavity, and carrying out chemical combination reaction with the oxygen when the aluminum alloy liquid is pressed into the pressure chamber and the die-casting die cavity to generate Al2O3The particles are distributed in the casting in a dispersed manner;
preheating is mainly used for preventing the metal liquid from being quenched rapidly and losing fluidity to cause forming failure or the surface of a part at the later stage from generating cracks or gaps even if forming is successful;
the casting is distributed in a scattered manner, so that the effect of reducing or eliminating pores of the casting can be achieved, and the compactness of the casting is improved;
and III, finally, moving the die casting machine from the injection punch to the state that the die cavity is filled until pressurization is finished.
As a further improvement of the manufacturing method of the present invention, the injection pressure is 50MPa, the in-gate velocity at the time of filling is 60m/s, the filling time is 0.1s, and the holding pressure time is 4 s.
The method comprehensively considers the size, shape, complexity, wall thickness, alloy characteristics, temperature and performance of the die casting.
The front connecting piece and the rear connecting piece are mainly used for transmitting the front collision force, the aluminum alloy has an energy absorption effect, the collision is buffered, and the weight of a car body can be reduced.
As a further improvement of the manufacturing method, the aluminum alloy material adopted for casting comprises 1 percent of silicon, 0.75 percent of magnesium, 0.25 percent of zinc, 0.20 percent of manganese, 0.15 percent of copper, 0.15 percent of iron, 0.10 percent of chromium, 0.10 percent of titanium, less than or equal to 0.3 percent of inevitable impurities, and the balance of aluminum.
The alloy material mainly comprises silicon and magnesium, has good processing performance, good corrosion resistance and excellent mechanical property, combines the advantages of high tensile strength, large yield strength and good ductility, and can be used for forming high-strength extrusion alloy.
The invention relates to a vehicle structure for resisting head-on collision, which forms a transverse closed loop of a front anti-collision beam, an energy absorption box, a front longitudinal beam and a firewall cross beam on a horizontal plane. And forming a front connecting piece, a threshold beam, a rear connecting piece and a longitudinal closing frame of the side frame on the longitudinal plane. Under the working condition of frontal collision, the three closed loops can effectively reduce the deformation of the vehicle body and improve the energy absorption effect, thereby protecting the safety of passengers.
All the beams and the frames are processed by extrusion, stretch bending and molding, and the front connecting piece and the rear connecting piece are molded by casting, so that the design and the process flow of the vehicle body can be effectively simplified.
The vehicle structure resisting head-on collision has the advantages of high integration level of parts, simple structure and capability of effectively reducing the number of parts of a vehicle body; the parts are made of aluminum alloy, and the aluminum alloy has an energy absorption effect and can further meet the requirement of light weight on the basis of meeting the collision requirement.
Drawings
FIG. 1 is a schematic view of a vehicle according to the present invention configured to resist frontal impact.
FIG. 2 is a diagram of the force transfer path during a frontal impact of a frontal impact resistant vehicle construction according to the present invention.
Fig. 3 is a schematic view of the front connector structure.
Fig. 4 is a schematic view of the structure of the rear connector.
Reference numerals: 1. a front impact beam; 2. an energy absorption box; 3. a front longitudinal beam; 4. a front connector; 5. a firewall beam; 6. a threshold beam; 7. a rear connector; 8. a side frame; 9. the bottom plate rear cross beam.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of description and simplicity of description, but do not indicate or imply that the device or element being referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be construed as limiting the present invention; the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance; furthermore, unless expressly stated or limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, as they may be fixedly connected, detachably connected, or integrally connected, for example; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Example 1
Fig. 1-4 show a vehicle structure resistant to frontal impact, comprising an impact beam 1 at the front end of the vehicle body; the energy absorption boxes 2 are arranged at two ends of the back of the front anti-collision beam 1; a front longitudinal beam 3 mounted on the back of the energy absorption box 2; the front connecting piece 4 is arranged at the tail end of the front longitudinal beam 3; a firewall cross beam 5 arranged between the two front connecting pieces 4, and a threshold beam 6 arranged at the rear end of each front connecting piece 4; a rear connector 7 mounted at the rear end of the threshold beam 6; a side frame 8 arranged at the top of the front connecting piece 4 and the top of the rear connecting piece 7 and a bottom plate rear cross beam 9 arranged between the two rear connecting pieces 7; the vehicle body forms a transverse closed loop surrounded by a front anti-collision beam 1, an energy absorption box 2, a front longitudinal beam 3 and a firewall cross beam 5 on the horizontal plane; the vehicle body forms a longitudinal closed frame which is enclosed by the front connecting piece 4, the threshold beam 6, the rear connecting piece 7 and the side wall frame 8 on a longitudinal plane.
Because the front connecting piece 4 and the rear connecting piece 7 are used as connecting nodes to form a vehicle structure, the number and the weight of vehicle parts can be reduced, too many connecting accessories such as bolts and the like do not need to be used, a plurality of welding processes can be saved, because a transverse closed loop on a horizontal plane and a longitudinal closed frame on a longitudinal plane are formed, the safety performance in the frontal collision can be improved, the stress conduction is convenient, the accidental load generated by the collision is transmitted to the longitudinal closed frame from the transverse closed loop, the influence of the collision on the transverse closed loop is reduced, the safety of the front part of a vehicle body is ensured, the transverse closed loop and the longitudinal closed frame of the vehicle body combined structure share one front connecting piece 4, the installation is convenient, the force transmission path can be reduced, the breakage of a force transmission piece between the transverse closed loop and the longitudinal closed frame can be avoided, the frontal collision performance of the vehicle is influenced, in addition, due to the existence of the energy absorption box 2, the energy absorption effect of the transverse closed-loop structure is better than that of the longitudinal closed frame, part of impact energy can be reduced, and the rigidity of the longitudinal closed frame is higher, so that the integrity of a vehicle body can be ensured.
In the present embodiment, the front connecting member 4 is a cavity structure having a front end opening to which the front side member 3 is mounted; installing a side opening of the firewall beam 5; mounting the rear end opening of the threshold beam 6; the top surface of the front end part of the side wall frame 8 is provided with an opening, and the rear connecting piece 7 is also of a cavity structure and is provided with a front opening for mounting the threshold beam 6; the top opening of the rear end part of the side frame 8 is installed; the side of the mounting floor rear cross member 9 is open.
The front connecting piece 4 and the rear connecting piece 7 are both in a cavity structure, and a plurality of openings are arranged, so that other vehicle body force transmission parts can be conveniently installed, and a transverse closed loop and a longitudinal closed frame can be formed.
In this embodiment, the front connecting member 4 further has a front sub-frame mounting hole 401 and a front floor mounting surface 402 for mounting a front sub-frame on the bottom surface thereof, and a firewall bulkhead overlapping edge 403 on the top surface thereof, and the rear connecting member 7 further has a rear floor mounting surface 701 on the top surface of the front portion thereof, and a trunk floor mounting surface 703 and an overlapping edge 702 for connecting a rear suspension damping structure on the top surface of the rear portion thereof, and the rear connecting member 7 further has a boss, a tubular supporting pillar and a plurality of transverse and longitudinal crisscross reinforcing rib structures on the inner side surface thereof.
The front connecting piece 4 and the rear connecting piece 7 can be used as connecting nodes of other parts of the vehicle, and are provided with bosses, tubular supporting columns and a plurality of transverse and longitudinal crossed reinforcing rib structures to strengthen the connecting nodes, so that the strength and the rigidity of the nodes are ensured, and a transverse closed loop and a longitudinal closed frame are stable.
In the present embodiment
The energy absorption box 2, the front longitudinal beam 3, the firewall cross beam 5 and the threshold beam 6 are formed by extrusion of aluminum profiles; the front anti-collision beam 1 and the side frame 8 are formed by extrusion, stretch bending and molding; the front connecting member 4 and the rear connecting member 7 are formed by aluminum alloy casting.
The aluminium alloy extrusion shaping or extrusion stretch-bending shaping wholeness is good, and part self is difficult for scattering the frame, is favorable to the conduction of power, and the intensity and the rigidity of connected node can be guaranteed in the aluminium alloy casting shaping, and preceding connecting piece 4 and back connecting piece 7 regard as the connected node of a plurality of parts, and strong node is guaranteed in the casting shaping, can improve the integrality of automobile body, even if receive the striking back, also are difficult for scattering the frame.
Example 2
The invention also relates to the manufacturing method, which comprises the following steps:
s1: manufacturing an energy absorption box 2, a front longitudinal beam 3, a firewall cross beam 5, a threshold beam 6 and a side wall frame 8 by adopting an extrusion forming process; manufacturing a front anti-collision beam 1 and a side frame 8 by adopting an extrusion stretch bending forming process; manufacturing a front connecting piece 4 and a rear connecting piece 7 by adopting a casting forming process;
s2: the assembly of the vehicle body is performed using the components formed in step S1.
In the present embodiment, in step S1, the extrusion molding process includes the steps of:
(1) preparing a corresponding extrusion die according to the cross section shape of a part to be extruded, and fastening the extrusion die on a port of extrusion equipment;
(2) softening the material, heating the aluminum alloy ingot to 380-440 ℃, and performing laser cutting treatment on the aluminum material according to the required size to prepare a blank;
(3) putting the manufactured blank into the bottom of an extrusion die, enabling an extrusion device in extrusion equipment to advance to the extrusion die at a basically constant extrusion speed, extruding the aluminum alloy cast ingot, and completely extruding the aluminum alloy cast ingot from a die hole of the extrusion die to form an extrusion piece;
(4) tempering the extruded aluminum alloy section, preserving heat, and stretching and straightening the tempered aluminum alloy section to obtain a required part;
above step is applicable to energy-absorbing box 2, front longitudinal 3, prevents hot wall crossbeam 5, threshold roof beam 6, bottom plate rear beam 9, has the radian to two whole of preceding crashproof roof beam 1 and side wall frame 8, need stretch bending just can final fashioned part, still need carry on following step:
(5) next to the step (4), the aluminum alloy profile after stretching and straightening is parked for a certain time, the temperature is reduced to 100 ℃ after tempering, bending is carried out, the front anti-collision beam 1 is formed by one-time stretch bending, for the side wall frame 8, as shown in an example shown in fig. 1, the left and right stretch bending are carried out for 4 times in total respectively, the middle of the side wall frame 8 is fixed, the left side is firstly stretched and bent, the bending angle is not more than 30 degrees, the second bending angle is not more than 60 degrees, the first bending angle on the right side is not more than 60 degrees, and the second bending angle is not more than 30 degrees;
(6) carrying out artificial heat treatment on the bent aluminum alloy section at the temperature of about 180 ℃ to ensure that the part has enough yield strength and tensile strength after stretch bending
In this embodiment, in step S1, the front connecting member 4 and the rear connecting member 7 are formed by casting aluminum alloy, and the casting process is an oxygen-filling die-casting method, which includes the following specific steps:
I. preheating a mould at 200 ℃, and putting the smelted material into the mould;
II, closing the die to close the die to form a cavity and a pouring gate, injecting dry oxygen into an injection chamber and the cavity of the die-casting die through the gas injection hole to replace air and other gases in the cavity, and carrying out chemical combination reaction with the oxygen when the aluminum alloy liquid is pressed into the pressure chamber and the die-casting die cavity to generate Al2O3The particles are distributed in the casting in a dispersed manner;
preheating is mainly used for preventing the metal liquid from being quenched rapidly and losing fluidity to cause forming failure or the surface of a part at the later stage from generating cracks or gaps even if forming is successful;
the casting is distributed in a scattered manner, so that the effect of reducing or eliminating pores of the casting can be achieved, and the compactness of the casting is improved;
and III, finally, moving the die casting machine from the injection punch to the state that the die cavity is filled until pressurization is finished.
In this example, the shot pressure was 50MPa, the in-gate velocity at the time of filling was 60m/s, the filling time was 0.1s, and the holding pressure time was 4 s.
The method comprehensively considers the size, shape, complexity, wall thickness, alloy characteristics, temperature and performance of the die casting.
The front connecting piece 4 and the rear connecting piece 7 mainly have the functions of transmitting the front collision force, the aluminum alloy has an energy absorption effect, the collision is buffered, and the weight of a car body can be reduced.
In this embodiment, the aluminum alloy material used for casting is composed of 1% of silicon, 0.75% of magnesium, 0.25% of zinc, 0.20% of manganese, 0.15% of copper, 0.15% of iron, 0.10% of chromium, 0.10% of titanium, and less than or equal to 0.3% of unavoidable impurities, with the balance being aluminum.
The alloy material mainly comprises silicon and magnesium, has good processing performance, good corrosion resistance and excellent mechanical property, combines the advantages of high tensile strength, large yield strength and good ductility, and can be used for forming high-strength extrusion alloy.
Example 3
In fig. 1-4, the present invention provides a frontal impact resistant vehicle structure that includes a front impact beam 1, an energy absorption box 2, a front longitudinal beam 3, a front connector 4, a firewall cross beam 5, a threshold beam 6, a rear connector 7, a side frame 8, and a floor rear cross beam 9.
In the embodiment, the crash box 2, the front longitudinal beam 3, the front connecting member 4, the threshold beam 6, the rear connecting member 7 and the side frame 8 are all in a left-right symmetrical structure about the central axis of the vehicle.
In the embodiment, the front anti-collision beam 1 is positioned at the foremost edge of the structure, the rear surface of the front anti-collision beam is provided with the energy absorption boxes 2 which are bilaterally symmetrical, and the energy absorption boxes 2 are connected with the front anti-collision beam 1 and the front longitudinal beam 3 which is positioned at the coaxial rear part of the front anti-collision beam through CMT welding; the rear part of the front longitudinal beam 3 is provided with a front connecting piece 4, the threshold beam 6 is arranged behind the front connecting piece 4, and the front longitudinal beam 3 and the threshold beam 6 are arranged in tandem, extend into the cavity of the front longitudinal beam through an opening reserved in the front connecting piece 4 and are fixed by riveting; the firewall cross beam 5 is positioned behind the front longitudinal beam 3, in front of the threshold beam 6 and between the two front connecting pieces 4, and the firewall cross beam is connected with the two front connecting pieces 4 which are bilaterally symmetrical in series through welding; the rear part of the threshold beam 6 is riveted with the front part of the rear connecting piece 7, the side wall frame 8 is positioned right above the threshold beam 6, the front part of the side wall frame is welded and fixed with the front connecting piece 4, and the rear part of the side wall frame is welded and connected with the rear connecting piece 7; the bottom plate rear cross beam 9 is connected with the rear connecting pieces 7 which are bilaterally symmetrical through welding.
In this embodiment, the front anti-collision beam 1, the energy absorption box 2, the front longitudinal beam 3, the firewall cross beam 5, the threshold beam 6, the side wall frame 8 and the bottom plate rear cross beam 9 are all formed by extrusion, bending and integral forming, and the shape of an extrusion section can be defined according to the collision requirement so as to adapt to the collision working condition and simplify the design and the process.
Meanwhile, the front connecting piece 4 and the rear connecting piece 7 are respectively connected with the front longitudinal beam 3 and the threshold beam 6, the threshold beam 6 and the rear longitudinal beam in a transition structure, and meanwhile, the inner side and the outer side of the transition structure are also provided with a plurality of parts, namely inserting and installing points, and reinforcing ribs which are arranged for ensuring that the transition structure has enough strength. The front connecting member 4 is provided with openings for connecting with the front longitudinal beam 3, the threshold beam 6 and the firewall cross beam 5 in the front, rear and inner sides, and also comprises a front subframe mounting hole 401 as shown in fig. 3, wherein the front subframe can be fastened with the front connecting member 4 through bolts, a front floor mounting surface 402 and a firewall partition plate overlapping edge 403. The rear connecting member 7 includes a rear floor mounting surface 701, a trunk floor mounting surface 703 and a lap joint 702 connected to the rear overhang vibration damping structure as shown in fig. 4, in addition to the front rocker beam, the rear side member and the inner side connecting floor rear cross member 9. Meanwhile, in order to ensure the structural strength of the rear connecting piece 7, the inner side surface of the rear connecting piece is also provided with a plurality of bosses, tubular supporting columns and a plurality of transverse and longitudinal crisscross reinforcing rib structures.
In the embodiment, the cross section of the energy absorption box 2 is a hollow rectangle, the cross section of the front longitudinal beam 3 is in a shape of Chinese character 'ri', so that energy absorption materials can be conveniently put in, and the cross section of the rest of the energy absorption boxes and the frame can be in accordance with the shape; the front connecting piece 4 and the rear connecting piece 7 are of cavity opening structures, and openings are reserved at the front end and the rear end.
In the embodiment, the vehicle body forms a transverse closed loop of the front anti-collision beam 1, the energy absorption box 2, the front longitudinal beam 3 and the firewall cross beam 5 in the horizontal plane; the vehicle structure is formed by a plurality of closed annular structures, and the vehicle structure comprises a front connecting piece 4, a threshold beam 6, a rear connecting piece 7 and a longitudinal closed frame of a side wall frame 8, and can effectively improve the deformation resistance of the vehicle body in frontal collision.
In the embodiment, when the automobile is in a frontal collision, the buffering and energy absorbing effects of the transverse closed-loop structure at the front part of the automobile are better than those of the longitudinal closed frame, and the degree of invasion of a cab is reduced by absorbing impact force generated by collision as much as possible, so that the safety of passengers is protected; the longitudinal closed frame should be more rigid than the transverse closed loop structure for resisting deformation of the cabin.
In this embodiment, when a frontal collision occurs, the acting force generated by the collision is transmitted to the energy-absorbing box 2 along the front anti-collision beam 1, and then transmitted to the front longitudinal beam 3, the energy-absorbing box 2 and the front longitudinal beam 3 are crushed, crumpled and deformed and simultaneously absorb a part of the impact force, and due to the anti-collision design of the automobile, the deformation of the energy-absorbing box 2 and the front longitudinal beam 3 is large. The remaining force is split into two directions, one direction is along the front connecting piece 4, the side wall frame 8 is transmitted to the rear connecting piece 7, and is transmitted to the rear part of the vehicle through the rear connecting piece 7, the other direction is along the front connecting piece 4, the threshold beam 6 is transmitted to the rear connecting piece 7 and is finally transmitted to the rear part of the vehicle, and due to the fact that most of the force generated by collision is absorbed by the energy absorption box 2 and the front longitudinal beam 3, and due to the rigid design of the threshold beam 6 and the side wall frame 8, the deformation is small.
The invention provides a vehicle structure for resisting head-on collision, which can increase less weight and cost under the limited arrangement space of an automobile, simplify the design while ensuring the front collision performance, reduce parts and processing technological processes and meet the requirement of light weight.
The invention can form a transverse closed loop of the front anti-collision beam, the energy absorption box, the front longitudinal beam and the firewall cross beam on the horizontal plane. And forming a front connecting piece, a threshold beam, a rear connecting piece and a longitudinal closing frame of the side frame on the longitudinal plane. Under the working condition of frontal collision, the three closed loops can effectively reduce the deformation of the vehicle body and improve the energy absorption effect, thereby protecting the safety of passengers.
All the beams and the frames are processed by extrusion, stretch bending and molding, and the front connecting piece and the rear connecting piece are molded by casting, so that the design and the process flow of the vehicle body can be effectively simplified.
The invention has high integration level of parts and simple structure, and can effectively reduce the number of parts of the vehicle body; the parts are made of aluminum alloy, and the aluminum alloy has an energy absorption effect and can further meet the requirement of light weight on the basis of meeting the collision requirement.
The foregoing is a more detailed description of the invention in connection with specific preferred embodiments and it is not intended that the invention be limited to these specific details. For those skilled in the art to which the invention pertains, several equivalent substitutions or obvious modifications can be made without departing from the spirit of the invention, and all the properties or uses are considered to be within the scope of the invention.

Claims (4)

1. A method of manufacturing a vehicle structure resistant to frontal impact, the vehicle structure comprising a front impact beam (1) located at a front end of a vehicle body; the energy absorption boxes (2) are arranged at two ends of the back of the front anti-collision beam (1); a front longitudinal beam (3) arranged at the back of the energy absorption box (2); the device is characterized by also comprising a front connecting piece (4) arranged at the tail end of the front longitudinal beam (3); a firewall beam (5) arranged between the two front connecting pieces (4), and a threshold beam (6) arranged at the rear end of each front connecting piece (4); a rear connecting member (7) mounted at the rear end of the threshold beam (6); side wall frames (8) arranged at the top of the front connecting piece (4) and the top of the rear connecting piece (7) and a bottom plate rear cross beam (9) arranged between the two rear connecting pieces (7); the vehicle body forms a transverse closed loop surrounded by a front anti-collision beam (1), an energy absorption box (2), a front longitudinal beam (3) and a firewall cross beam (5) on the horizontal plane; the car body forms a longitudinal closed frame surrounded by a front connecting piece (4), a threshold beam (6), a rear connecting piece (7) and a side frame (8) on a longitudinal plane;
the front connecting piece (4) is of a cavity structure and is provided with a front end opening for mounting the front longitudinal beam (3); a side opening for installing the firewall beam (5); mounting a rear end opening of the threshold beam (6); the top surface opening is used for installing the front end part of the side wall frame (8), the rear connecting piece (7) is also of a cavity structure and is provided with a front opening used for installing the threshold beam (6); the top opening of the rear end part of the side frame (8) is installed; the side part of the bottom plate rear cross beam (9) is installed with an opening;
the bottom surface of the front connecting piece (4) is also provided with a front auxiliary frame mounting hole (401) for mounting a front auxiliary frame and a front floor mounting surface (402), the upper surface of the front connecting piece is also provided with a firewall clapboard overlapping edge (403), the upper surface of the front part of the rear connecting piece (7) is also provided with a rear floor mounting surface (701), the upper surface of the rear part is also provided with a trunk floor mounting surface (703) and an overlapping edge (702) for connecting a rear suspension damping structure, the inner side surface of the rear connecting piece (7) is also provided with a boss, a tubular supporting column and a plurality of transverse and longitudinal crisscross reinforcing rib structures;
the energy absorption box (2), the front longitudinal beam (3), the firewall cross beam (5) and the threshold beam (6) are formed by extrusion of aluminum profiles; the front anti-collision beam (1) and the side wall frame (8) are formed by extrusion, stretch bending and forming; the front connecting piece (4) and the rear connecting piece (7) are formed by casting aluminum alloy;
the manufacturing method specifically comprises the following steps:
s1: manufacturing the energy absorption box (2), the front longitudinal beam (3), the firewall cross beam (5), the threshold beam (6) and the side wall frame (8) by adopting an extrusion forming process; manufacturing the front anti-collision beam (1) and the side frame (8) by adopting an extrusion stretch bending forming process; manufacturing the front connecting piece (4) and the rear connecting piece (7) by adopting a casting forming process;
s2: assembling the vehicle body using the components formed in step S1;
in step S1, the extrusion molding process includes the steps of:
(1) preparing a corresponding extrusion die according to the cross section shape of a part to be extruded, and fastening the extrusion die on a port of extrusion equipment;
(2) softening the material, heating the aluminum alloy ingot to 380-440 ℃, and performing laser cutting treatment on the aluminum material according to the required size to prepare a blank;
(3) putting the manufactured blank into the bottom of an extrusion die, enabling an extrusion device in extrusion equipment to advance to the extrusion die at a constant extrusion speed, extruding the aluminum alloy cast ingot, and completely extruding the aluminum alloy cast ingot from a die hole of the extrusion die to form an extrusion piece;
(4) tempering the extruded aluminum alloy section, preserving heat, and stretching and straightening the tempered aluminum alloy section to obtain a required part;
above step is applicable to energy-absorbing box (2), front longitudinal (3), prevents hot wall crossbeam (5), threshold roof beam (6), bottom plate rear frame member (9), has the radian to two whole of preceding crashproof roof beam (1) and side wall frame (8), need stretch-bending just can final fashioned part, still need carry out following step:
(5) next, the aluminum alloy profile after stretching and straightening is parked for a certain time, the aluminum alloy profile after tempering is bent after the temperature is reduced to 100 ℃, the front anti-collision beam (1) is formed by one-time stretch bending, the side wall frame (8) needs to be subjected to the total stretch bending of 4 times for each time in the left and right directions, the middle of the side wall frame (8) is fixed, the left side is firstly subjected to the stretch bending, the bending angle is not more than 30 degrees, the second bending angle is not more than 60 degrees, the first bending angle on the right side is not more than 60 degrees, and the second bending angle is not more than 30 degrees;
(6) and (3) carrying out artificial heat treatment on the bent aluminum alloy section at the temperature of 180 ℃.
2. The method for manufacturing a head-on collision resistant vehicle structure according to claim 1, wherein in step S1, the front connecting member 4 and the rear connecting member 7 are cast of aluminum alloy and the casting process is an oxygen die casting method, and the method includes the following steps:
I. preheating a mould at 200 ℃, and putting the smelted material into the mould;
II, closing the die to close the die to form a cavity and a pouring gate, injecting dry oxygen into an injection chamber and the cavity of the die-casting die through the gas injection hole to replace air and other gases in the cavity, and carrying out chemical combination reaction with the oxygen when the aluminum alloy liquid is pressed into the pressure chamber and the die-casting die cavity to generate Al2O3The particles are distributed in the casting in a dispersed manner;
and III, finally, moving the die casting machine from the injection punch to the state that the die cavity is filled until pressurization is finished.
3. The method for manufacturing a head-on collision resistant vehicle structure according to claim 2, wherein the shot pressure is 50MPa, the in-gate speed at the time of filling is 60m/s, the filling time is 0.1s, and the hold pressure time is 4 s.
4. The method for manufacturing a head-on collision resistant vehicle structure according to claim 2, wherein the aluminum alloy material for casting is composed of 1% of silicon, 0.75% of magnesium, 0.25% of zinc, 0.20% of manganese, 0.15% of copper, 0.15% of iron, 0.10% of chromium, 0.10% of titanium, 0.3% or less of unavoidable impurities, and the balance of aluminum.
CN202011582416.0A 2020-12-28 2020-12-28 Head-on collision resistant vehicle structure and manufacturing method Active CN112622795B (en)

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CN203345037U (en) * 2013-05-27 2013-12-18 广州汽车集团股份有限公司 Automobile body frame structure
CN106882272A (en) * 2015-12-16 2017-06-23 广州汽车集团股份有限公司 Forward engine room frame assembly
CN209757261U (en) * 2019-02-28 2019-12-10 重庆长安汽车股份有限公司 Connecting structure of front longitudinal beam of aluminum alloy vehicle body
CN110434308A (en) * 2019-08-28 2019-11-12 杭州富阳宏泰精密铸件有限公司 A kind of die-casting process process
CN111547134A (en) * 2020-04-23 2020-08-18 广汽蔚来新能源汽车科技有限公司 Vehicle, vehicle body and force transmission structure thereof

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