CN113312701B - Topology and size optimization-based all-aluminum passenger car body door column structure design method - Google Patents
Topology and size optimization-based all-aluminum passenger car body door column structure design method Download PDFInfo
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Abstract
The invention discloses a topology and size optimization-based all-aluminum passenger car body door column structure design method, which comprises the following steps: carrying out torsional rigidity calculation on a passenger car model with a door upright post; establishing an initial model of a door upright post; establishing a topology optimization scheme for the initial model of the door upright post to obtain a topological model; constraint conditions of the topology optimization scheme comprise limiting the maximum relative displacement at a loading point of an applied load during torsional rigidity calculation, wherein a calculation formula of the relative displacement is as follows: func (U) 1 ,U 2 )＝U 1 ‑U 2 Wherein U is 1 、U 2 Is the vertical displacement at the loading point; and taking the model after the topological model is read as an initial model of size optimization, establishing a size optimization scheme, and calculating torsional rigidity of the obtained final optimized structure model to obtain the torsional rigidity of the optimized passenger car model. The invention can fully exert the technical effects of topology and size optimization, and ensure that the torsion rigidity of the whole vehicle is improved on the premise of meeting the light weight of the door upright post.
Description
Technical Field
The invention belongs to the technical field of structural optimization analysis, and particularly relates to a structural design method of an all-aluminum passenger car body door column based on topology and size optimization.
Background
The lightweight design technology of automobiles has become one of the research hotspots in the current automobile research field. The development of the existing main engine factories and aluminum enterprises in China mainly uses the design experience of the steel car body to replace the steel with aluminum instead of steel to replace the steel with equal rigidity, the special advantage of the section of the aluminum profile is ignored, the characteristic that the density of aluminum materials is lighter than that of steel is only considered, the development of the section of the aluminum profile is relatively vacant, in the design and development, reverse design is mostly adopted, namely, the car structure is designed through experience and then subjected to CAE analysis to carry out performance check, the design and development flow can lead to the designed structural performance to be smaller or excessive, the performance requirement can not be met accurately, the repeated design and verification are needed, the number of iterations is large, and the development period is slow.
In addition, in the design development process of the all-aluminum passenger car body, the car body door upright post is used as a main bearing structure of the car body side wall, and when the design is carried out, the requirements of rigidity can be met, meanwhile, the weight reduction can be realized, the design of the door upright post is mainly based on experience design, the advantage of complex cross section shape of the aluminum profile is not fully exerted, the design is carried out by adopting a simple section, and the real value of the aluminum profile is hardly embodied.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides the structural design method of the all-aluminum passenger car body door upright post based on topology and size optimization, which can fully exert the technical effects of topology and size optimization and ensure that the torsional rigidity of the whole car is improved on the premise of meeting the light weight of the door upright post.
The invention adopts the following technical scheme:
the method for designing the structure of the all-aluminum passenger car body door upright post based on topology and size optimization is characterized by comprising the following steps of:
(1) Carrying out torsional rigidity calculation on a passenger car model with a door upright post;
(2) Establishing a door upright post initial model, wherein the outline of the door upright post initial model is completely filled by adopting entity units;
(3) Establishing a topology optimization scheme for the initial model of the door upright post to obtain a topological model; the topology optimization scheme comprises a first design variable, constraint conditions and a first target response; the first design variable is all filling areas in the outline of the initial model of the door upright post; the constraint condition includes limiting the relative displacement at the loading point to which the load is applied in the torsional rigidity calculation, and the calculation formula of the relative displacement is: func (U) 1 ,U 2 )＝U 1 -U 2 Wherein U is 1 、U 2 Is the vertical displacement at the loading point; the first target response is volume fraction minimization; the topology optimization scheme comprises the steps of performing pattern repeated setting and extrusion path setting of a solid model on design variables;
(4) Taking the model after the model is read after topology as an initial model of size optimization, and establishing a size optimization scheme to obtain a final optimization structure model; the size optimization scheme comprises a second design variable, a constraint function and a second target response; the second design variable is the wall thickness of different positions of the section of the door upright post; the constraint function is used for limiting the relative displacement of a loading point of a load applied during the calculation of the maximum mass and the torsional rigidity of the door upright; the second target response is stiffness maximization;
(5) And (3) carrying out torsional rigidity calculation on the final optimized structure model to obtain the torsional rigidity of the optimized passenger car model.
The method for designing the door upright post structure of the all-aluminum passenger car body based on topology and size optimization is characterized in that a passenger car model containing the door upright post in the step (1) is modeled by adopting a shell unit; the door upright post comprises a front door rear upright post of a passenger car, a front door front upright post of the passenger car and a rear door rear upright post of the passenger car, and is an aluminum alloy section.
The method for designing the all-aluminum passenger car body door upright post structure based on topology and size optimization is characterized in that boundary conditions adopted in the step (1) are that the translational degree of freedom is restrained X, Y, Z at the center point positions of the front and rear plate springs of two rear wheels of a passenger car chassis, the load applied by the torsional rigidity calculation is a pair of couples, and the application positions of the couples are the center point positions of the front and rear plate springs of the left front wheel of the passenger car and the center point positions of the front and rear plate springs of the right front wheel of the passenger car respectively.
The topology and size optimization-based all-aluminum passenger car body door upright post structure design method is characterized in that the constraint conditions in the step (3) further comprise first-class response constraints, and the first-class response constraints limit the maximum displacement of the door upright post initial model in the step (2), the maximum displacement of the passenger car front door rear upright post, the maximum displacement of the passenger car rear door front upright post and the maximum displacement of the passenger car rear door rear upright post.
The method for designing the door upright post structure of the all-aluminum passenger car body based on topology and size optimization is characterized in that in the step (2), after conceptual design is carried out on the door upright post, an initial model of the door upright post is established, the initial model of the door upright post is a solid model, and the outline of the initial model of the door upright post is identical to that of the door upright post of the passenger car with the door upright post.
The method for designing the all-aluminum bus body door upright post structure based on topology and size optimization is characterized in that the cross sections of the door upright posts of the topology rear model in the extrusion direction are identical, the sections of the front door rear upright post of the bus, the section of the front door rear upright post of the bus and the section of the rear door rear upright post of the bus in the topology rear model are identical, and the wall thicknesses of the same positions of the sections of the door upright posts are identical design variables; the calculation formula of the relative displacement in the step (4) is the same as the calculation formula of the relative displacement in the step (3).
The structural design method of the all-aluminum passenger car body door upright post based on topology and size optimization is characterized in that the formula for calculating torsional rigidity in the step (1) is as follows: k (K) T T/θ, where T is torque and θ is torsion angle.
The beneficial technical effects of the invention are as follows: the torsional rigidity of the optimized passenger car model is improved compared with the rigidity of the whole car model based on the existing door upright post. According to the invention, by utilizing the section characteristics of the aluminum profile and through topology and size optimization technology, the optimal aluminum profile rib distribution mode and wall thickness size distribution are obtained, the functions of the topology and size optimization technology are fully exerted, and the torsional rigidity of the whole vehicle is improved on the premise of meeting the light weight of the door upright post.
Drawings
FIG. 1 is a technical roadmap of the method of the invention;
FIG. 2 is a finite element model of the whole vehicle of the present invention;
FIG. 3 is a graphical illustration of the boundary conditions and load application of the vehicle model of FIG. 2 in accordance with the present invention;
FIG. 4 is a displacement cloud of the vehicle model of FIG. 2 according to the present invention;
FIG. 5 is a cross-sectional view of an initial model of the door pillar conceptual design of the present invention;
FIG. 6 is a door pillar extrusion path diagram of the present invention;
FIG. 7 is a door pillar topology optimization calculation result of the present invention;
FIG. 8 is an initial model of the post-interpretation dimensional optimization of FIG. 7 in accordance with the present invention;
FIG. 9 is a dimensional optimal design variable of the present invention;
fig. 10 is a complete vehicle model displacement cloud chart based on the door pillar optimization structure.
Detailed Description
The technical scheme of the invention is further described below with reference to the accompanying drawings and specific embodiments. It should be understood that the described embodiment is one of an implementation or a preferred implementation of the present invention, and the present invention is not limited to the described embodiment.
Referring to fig. 1-10, the invention discloses a topology and size optimization-based all-aluminum passenger car body door column structure design method, which is characterized by comprising the following steps:
(1) Carrying out torsional rigidity calculation on a passenger car model based on the existing door upright post (or the original door upright post); the door upright post is used as a part of a passenger car structure, is complex in stress, is difficult to be independent from the whole passenger car, and is difficult to obtain working conditions, so that torsional rigidity analysis is performed on the whole passenger car model. Modeling the passenger car model by adopting a shell unit; the existing door upright posts comprise three door upright posts, namely a front door rear upright post 1 of a passenger car, a rear door front upright post 2 of the passenger car and passengersAnd the rear column 3 of the rear door of the vehicle is an aluminum alloy section. The boundary condition adopted by the torsional rigidity calculation is that the translational degree of freedom is restrained X, Y, Z at the position of a central point coupled with the front and rear plate springs of the left and right rear wheels of the chassis of the passenger car, the load applied by the torsional rigidity calculation is a pair of couples (F-F), and the application positions of the couples (F-F) are the position of the central point coupled with the front and rear plate springs of the left front wheel of the passenger car and the position of the central point coupled with the front and rear plate springs of the right front wheel of the passenger car respectively. The formula for the torsional stiffness calculation is: k (K) T T/θ, where T is torque and θ is torsion angle.
(2) And (3) carrying out conceptual design on the door upright, establishing a door upright initial model, wherein the outer contour of the door upright initial model is the same as that of the existing door upright, the door upright initial model is a solid model, the length and the section outer contour of the door upright are the same as those of the existing door upright, and the interior of the contour of the door upright initial model is completely filled by adopting solid units.
(3) Establishing a topology optimization scheme for the initial model of the door upright post; the topology optimization scheme comprises three elements, namely a first design variable, a constraint condition and a first target response; the first design variable is all filling areas in the outline of the three door upright post initial models, and the filling areas are solid units. The constraint conditions comprise a first type of response constraint and a second type of response constraint, wherein the first type of response constraint is used for limiting the maximum displacement of an initial model of a door upright post, the maximum displacement of a front door rear upright post of a passenger car, the maximum displacement of a front upright post of the rear door of the passenger car and the maximum displacement of a rear upright post of the rear door of the passenger car; the second type of response constraint is to limit the relative displacement at the loading point where the load is applied during the torsional stiffness calculation, which is obtained by building an equation: func (U) 1 ,U 2 )＝U 1 -U 2 Wherein U is 1 、U 2 Is the vertical displacement at the loading point. The first target response is volume fraction minimization. The topology optimization scheme comprises the mode repetition setting and extrusion path setting of the entity model for the design variables.
And submitting calculation to solve to obtain a topological model.
(4) Reading the topological model, taking the read model as an initial model of size optimization, and establishing a size optimization scheme; the initial model is a door column model obtained by considering an actual process on the basis of topology optimization. The size optimization scheme comprises three elements, namely a second design variable, a constraint function and a second target response; the second design variable is the wall thickness of the sections of the three door uprights at different positions, and the wall thickness of the sections of the three door uprights at the same position is the same design variable; the constraint function is to limit the relative displacement at the loading point of the load applied during the calculation of the maximum mass and torsional rigidity of the door pillar, and the calculation formula of the relative displacement is the same as that of the relative displacement in the step (3). The second target response is stiffness maximization. The sections and the sizes of the three door uprights are identical.
Submitting calculation to solve to obtain a final optimized structure model of the three door uprights;
(5) And (3) carrying out torsional rigidity calculation on the final optimized structural model based on the door upright post to obtain the torsional rigidity of the optimized passenger car model.
Example 1
Step (1): and carrying out torsional rigidity calculation on the passenger car model based on the existing door upright post. The existing door uprights comprise three door uprights which are respectively a front door rear upright 1 of a passenger car, a rear door front upright 2 of the passenger car and a rear door rear upright 3 of the passenger car, and are aluminum alloy sections. Firstly, preprocessing a whole bus model, carrying out finite element modeling by adopting a shell unit, and endowing each part of the structure with corresponding thickness, wherein the whole bus model is shown in fig. 2, the boundary condition is that the translational degree of freedom is restrained X, Y, Z at the center point position of the coupling of the front and rear leaf springs of the left and right rear wheels of the chassis, the load is a pair of couples (F-F) applied in the vertical direction, the magnitude is 47230N, and the applied positions are the center point position of the coupling of the front and rear leaf springs of the left front wheel of the chassis and the center point position of the coupling of the front and rear leaf springs of the right front wheel, as shown in fig. 3.
And after the pretreatment is finished, submitting and calculating to obtain that the maximum displacement of the whole vehicle model is 42.57mm, the maximum displacement of the front door rear upright post is 36.26mm, the maximum displacement of the rear door front upright post is 21.83mm, the maximum displacement of the rear door rear upright post is 19.15mm, and the vertical relative displacement of the loading point is: u (U) 1 -U 2 =15.85 mm, displacement cloud as shown in fig. 4As shown.
The torsional rigidity of the existing whole vehicle model can be obtained by the following formula:
wherein K is T Is the torsional rigidity (N.m/deg) of the whole vehicle model, T is torque, theta is torsion angle, deltaU is the relative displacement of loading point, U 1 ，U 2 For displacement at the loading point, F is the applied load and L is the distance between the two loading points.
Calculated to obtain the torsional rigidity K T ＝29096N·m/deg。
Step (2): and (3) carrying out conceptual design on the door upright, establishing a door upright initial model, wherein the door upright initial model is a solid model, the length and the section outline of the door upright are the same as those of the existing door upright, and the outline of the door upright initial model is completely filled by adopting solid units.
Step (3): establishing a topology optimization scheme for the initial model of the door upright post; and defining three elements of the topology optimization scheme, namely a first design variable, a constraint condition and a first target response. The first design variable is all filling areas in the outline of the three door upright post initial models, and the filling areas are solid units.
The constraint conditions include a first type of response constraint and a second type of response constraint, the first type of response constraint including: (1) limiting the node displacement of the maximum displacement of the existing whole vehicle model to be not more than 42.57mm, (2) limiting the node displacement of the maximum displacement of the front door and rear upright post to be not more than 36.26mm, (3) limiting the node displacement of the maximum displacement of the rear door and front upright post to be 21.83mm, and (4) limiting the node displacement of the maximum displacement of the rear door and rear upright post to be not more than 19.15mm. The second type of response constraint is to limit the relative displacement at the loading point where the load is applied in torsional stiffness calculation to be no more than 15.85mm, and in topology optimization, the relative displacement value cannot be directly input, and is obtained by defining an equation, which is func (U 1 ,U 2 )＝U 1 -U 2 。
The first target response is that the volume fraction is minimized so that the door pillar can be maximally light-weighted. The topology optimization scheme comprises the mode repetition setting and extrusion path setting of the entity model for the design variables.
In the topology optimization analysis process, in order to realize that the optimized door stand column is manufactured by adopting a profile, the extrusion path direction is designated for the design variable, so that the cross section of the material along the extrusion direction is kept consistent, and the extrusion path of the door stand column is shown in fig. 6. In addition, in order to reduce the workload of mold design and manufacturing processing, the design variables are repeatedly set in a pattern of a solid model, so that the structural styles of the three door pillar design areas are completely the same.
And submitting calculation to solve to obtain a topological model, wherein the topological optimization calculation result of the door column is shown in fig. 7.
Step (4): and reading the topological model, taking the read model as an initial model of size optimization, and establishing a size optimization scheme.
According to the actual process, four corners of the cross section of the profile are piled up, extrusion of the profile is not facilitated, and the material pile is easy to cause mass bias, so that reinforcing ribs can be added at four corner positions when the door upright post after topology is read, and an initial model of size optimization after reading is shown in fig. 8.
Defining three elements of a size optimization scheme, namely a second design variable, a constraint function and a second target response; the second design variable is the wall thickness of the sections of the three door uprights at different positions, the wall thickness of the sections of the three door uprights at the same position is the same design variable, the size optimization design variable is shown in fig. 9, the initial wall thickness of the design variable, and the wall thickness optimization interval and the optimization step length are set in table 1:
table 1 example 1 wall thickness optimization interval and optimization step setting
The constraint is that the maximum mass of the door pillar is limited to be not more than 27.7kg, the relative displacement at the loading point is limited to be not more than 15.85mm, and the definition of the relative displacement is the same as that in the step (3).
The second target response is rigidity maximization, so that the rigidity of the whole vehicle can be improved to the greatest extent on the premise of light weight of the door upright post.
And submitting calculation to solve to obtain a final optimized structural model of the three door uprights, wherein the total mass and the wall thickness of each part of the three optimized door uprights are shown in table 2, and compared with the existing door uprights, the optimized door uprights have the mass reduced by 0.42kg.
Table 2 example 1 total mass of three door posts optimized and wall thickness of each part
Step (5): and (3) carrying out torsional rigidity calculation on the final optimized structural model based on the door upright post to obtain the torsional rigidity of the optimized passenger car model. The final optimized door upright post structure is replaced into a whole vehicle model, torsional rigidity calculation is carried out on the new whole vehicle model according to boundary conditions and loading modes, the calculation result of the whole vehicle model based on the door upright post optimized structure is obtained, the maximum displacement of the new whole vehicle model is 42.37mm, the maximum displacement of a front door rear upright post is 36.04mm, the maximum displacement of a rear door front upright post is 21.82mm, the maximum displacement of a rear door rear upright post is 19.19mm, and the vertical relative displacement at a loading point is: u (U) 1 -U 2 Displacement cloud is shown in fig. 10, = 15.787 mm.
Torsional rigidity of the new whole vehicle model is according to K T Calculating by a calculation formula to obtain a torsional rigidity value K of the new whole vehicle model T Compared with the existing whole vehicle model, the rigidity K of the model is 29215 N.m/deg T = 29096n·m/deg promotes 119n·m/deg.
From the description of the above embodiments, it is clear for those skilled in the art that the present invention is based on the topology and size optimization of the structural design method of the all-aluminum passenger car body door pillar.
The above embodiments are only for illustrating the technical solution of the present invention and not for limiting the same, and although the present invention has been described in detail with reference to the above embodiments, one skilled in the art may make modifications and equivalents to the specific embodiments of the present invention, and any modifications and equivalents thereof without departing from the spirit and scope of the present invention are within the scope of the claims of the present invention.
Claims (7)
1. The method for designing the structure of the all-aluminum passenger car body door upright post based on topology and size optimization is characterized by comprising the following steps of:
(1) Carrying out torsional rigidity calculation on a passenger car model with a door upright post;
(2) Establishing a door upright post initial model, wherein the outline of the door upright post initial model is completely filled by adopting entity units;
(3) Establishing a topology optimization scheme for the initial model of the door upright post to obtain a topological model; the topology optimization scheme comprises a first design variable, constraint conditions and a first target response; the first design variable is all filling areas in the outline of the initial model of the door upright post; the constraint condition includes limiting the relative displacement at the loading point to which the load is applied in the torsional rigidity calculation, and the calculation formula of the relative displacement is: func (U) 1 ,U 2 )＝U 1 -U 2 Wherein U is 1 、U 2 Is the vertical displacement at the loading point; the first target response is volume fraction minimization; the topology optimization scheme comprises the steps of performing pattern repeated setting and extrusion path setting of a solid model on design variables;
(4) Taking the model after the model is read after topology as an initial model of size optimization, and establishing a size optimization scheme to obtain a final optimization structure model; the size optimization scheme comprises a second design variable, a constraint function and a second target response; the second design variable is the wall thickness of different positions of the section of the door upright post; the constraint function is used for limiting the relative displacement of a loading point of a load applied during the calculation of the maximum mass and the torsional rigidity of the door upright; the second target response is stiffness maximization;
(5) And (3) carrying out torsional rigidity calculation on the final optimized structure model to obtain the torsional rigidity of the optimized passenger car model.
2. The topology and size optimization-based all-aluminum passenger car body door pillar structure design method according to claim 1, wherein the passenger car model containing the door pillar in the step (1) is modeled by adopting a shell unit; the door upright post comprises a front door rear upright post of a passenger car, a front door front upright post of the passenger car and a rear door rear upright post of the passenger car, and is an aluminum alloy section.
3. The method for designing the door pillar structure of the all-aluminum passenger car body based on topology and size optimization according to claim 2, wherein the boundary condition adopted in the step (1) for calculating the torsional rigidity is that the translational degree of freedom is restrained X, Y, Z at the central point position coupled with the front and rear leaf springs of the two rear wheels of the passenger car chassis, the load applied by the torsional rigidity calculation is a pair of couples, and the application positions of the couples are the central point position coupled with the front and rear leaf springs of the left front wheel of the passenger car and the central point position coupled with the front and rear leaf springs of the right front wheel of the passenger car respectively.
4. The topology and size optimization-based all-aluminum passenger car body upright post structure design method according to claim 2, wherein the constraint conditions in the step (3) further comprise a first type of response constraint, and the first type of response constraint is used for limiting the maximum displacement of the initial model of the door upright post in the step (2), the maximum displacement of the front door and the rear upright post of the passenger car, the maximum displacement of the front upright post of the rear door of the passenger car and the maximum displacement of the rear upright post of the rear door of the passenger car.
5. The method for designing the door column structure of the all-aluminum passenger car body based on topology and size optimization according to claim 1, wherein in the step (2), after the door column is conceptually designed, an initial door column model is built, the initial door column model is a solid model, and the outer contour of the initial door column model is the same as that of the door column of the passenger car with the door column.
6. The method for designing the door upright post structure of the all-aluminum passenger car body based on topology and size optimization according to claim 2, wherein the cross sections of the door upright posts of the topology rear model in the extrusion direction are identical, the sections of the front door upright post of the passenger car, the section of the front upright post of the rear door of the passenger car and the section of the rear door upright post of the passenger car in the topology rear model are identical, and the wall thicknesses of the sections of the door upright posts at the same position are identical design variables; the calculation formula of the relative displacement in the step (4) is the same as the calculation formula of the relative displacement in the step (3).
7. The topology and size optimization-based all-aluminum passenger car body door pillar structure design method according to claim 2, wherein the formula of the torsional rigidity calculation in the step (1) is as follows: k (K) T T/θ, where T is torque and θ is torsion angle.
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