【优化设计大赛】汽车全塑前端框架二次拓扑优化科研
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><strong style="color: blue;"><strong style="color: blue;"><span style="color: black;">本文为技术邻·Altair优化设计大赛投稿作品，作者为技术邻用户：</span></strong><strong style="color: blue;"><span style="color: black;">孙正峰，</span></strong><strong style="color: blue;"><span style="color: black;"><span style="color: black;">倘若</span><span style="color: black;">爱好</span>务必点击文末 </span></strong><span style="color: black;"><strong style="color: blue;">阅读原文 </strong></span><strong style="color: blue;"><span style="color: black;"><strong style="color: blue;"><span style="color: black;">支持作者，为他投票哦！</span></strong></span></strong></strong></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><strong style="color: blue;">1 </strong><strong style="color: blue;">拓扑优化数学模型的<span style="color: black;">创立</span></strong></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;">连续体结构拓扑优化数学模型如公式（1）所示：</p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/lR4GOtoy9vL0ZZp6Aueia7n3h9Rb3ZuNXq9lGzeveBU2YlFpQoNDuxCTDDQPWyvoTtnjhFH6r09Y753XLQ94jSQ/640?wx_fmt=png&tp=webp&wxfrom=5&wx_lazy=1&wx_co=1" style="width: 50%; margin-bottom: 20px;"></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><strong style="color: blue;">2 </strong><strong style="color: blue;">拓扑优化有限元模型的<span style="color: black;">创立</span></strong></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><strong style="color: blue;">2.1 </strong><strong style="color: blue;">网格划分</strong></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;">为了反映拓扑优化后前端框架加强筋的宽度以及料厚的分布<span style="color: black;">状况</span>，设计前端框架拓扑优化分析的单元类型为四面体网格，单元尺寸<span style="color: black;">体积</span>为1.5mm，其余金属部件（除拉铆螺母、嵌件等部件）抽取中面进行四边形网格划分，单元尺寸为4.0mm。</p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><strong style="color: blue;">2.2 </strong><strong style="color: blue;">材料与属性</strong></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;">计算中所<span style="color: black;">运用</span>的材料参数见表1，长度单位为：mm。全塑前端框架真实应力-应变关系曲线如图1所示，<span style="color: black;">思虑</span>玻纤取向的影响，<span style="color: black;">因此呢</span>，其弹性模量选择玻纤45°方向。</p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/lR4GOtoy9vL0ZZp6Aueia7n3h9Rb3ZuNXF52I5s1Vm0CUtva6bMkswwDFg1GjCVjYtYUviaZnTHCMx7JIkMZPDNw/640?wx_fmt=png&tp=webp&wxfrom=5&wx_lazy=1&wx_co=1" style="width: 50%; margin-bottom: 20px;"></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><strong style="color: blue;">2.3 </strong><strong style="color: blue;">边界<span style="color: black;">要求</span>及载荷工况</strong></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;">约束：与车身环境件安装孔连接处采用固定约束，金属部件之间以及前防撞梁的连接采用刚性连接以及焊接处理。</p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;">载荷：常温，锁扣刚度，锁扣受力，F+x=1000N，F+z=1000N；锁扣强度，锁扣受力，F+z=3500N；高温80℃，散热器安装点刚度，F+x=600N，F-z=600N。</p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">掌控</span><span style="color: black;">要求</span>：各个工况下全塑前端框架的位移变形和断裂强度，一阶固有频率。</p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;">约束<span style="color: black;">要求</span>：锁扣刚度，全塑前端框架X向最大变形量≤7mm，Z向最大变形量≤2mm，最大应力≤75×0.8=60MPa；一阶固有频率≥35Hz；高温下，散热器安装点最大变形量≤1mm。</p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">目的</span>：设计区域总体积最小。</p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><strong style="color: blue;">2.4</strong><strong style="color: blue;">拓扑优化有限元模型</strong></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/lR4GOtoy9vL0ZZp6Aueia7n3h9Rb3ZuNXAWh0RRicnHmCaIjgUgTgZ8cUMnuYzOTve5MI5SSiap1BI0PRCU8MkkcA/640?wx_fmt=gif&tp=webp&wxfrom=5&wx_lazy=1&wx_co=1" style="width: 50%; margin-bottom: 20px;">全塑前端框架拓扑优化模型分为设计区与非设计区，设计区即为拓扑优化区，非设计区为安装孔位置、空滤进口位置、所有金属部件。其拓扑优化模型如图2所示：</p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/lR4GOtoy9vL0ZZp6Aueia7n3h9Rb3ZuNXnc2F9ZQb1oibGRDFlqASiaXFhmhb4kRR6ialjUoSZwtQ856CVQXT6yZvw/640?wx_fmt=png&tp=webp&wxfrom=5&wx_lazy=1&wx_co=1" style="width: 50%; margin-bottom: 20px;"></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><strong style="color: blue;">3 </strong><strong style="color: blue;">分析结果</strong></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><strong style="color: blue;">3.1 </strong><strong style="color: blue;"><span style="color: black;">第1</span>次拓扑优化分析结果</strong></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">经过</span>拓扑优化分析，得到全塑前端框架密度分布云图，将密度结果分布云图以STL格式导出，再<span style="color: black;">经过</span>三维软件进行3D数据设计，如图3所示：</p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/lR4GOtoy9vL0ZZp6Aueia7n3h9Rb3ZuNXVwia7jjU1GicwWd1HaI6CqQTNaQ5ia9uVd9WDYpu3EETVOySHPSvribtqg/640?wx_fmt=png&tp=webp&wxfrom=5&wx_lazy=1&wx_co=1" style="width: 50%; margin-bottom: 20px;"></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/lR4GOtoy9vL0ZZp6Aueia7n3h9Rb3ZuNXAWh0RRicnHmCaIjgUgTgZ8cUMnuYzOTve5MI5SSiap1BI0PRCU8MkkcA/640?wx_fmt=gif&tp=webp&wxfrom=5&wx_lazy=1&wx_co=1" style="width: 50%; margin-bottom: 20px;">锁扣刚度工况，全塑前端框架拓扑优化前后变形分布云图如图4所示：</p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/lR4GOtoy9vL0ZZp6Aueia7n3h9Rb3ZuNXYicvYecpFwibP4fOzJ19a8Q1vqTJO5ju2BneHrCia8jFYm8iaEQBtnJZHA/640?wx_fmt=png&tp=webp&wxfrom=5&wx_lazy=1&wx_co=1" style="width: 50%; margin-bottom: 20px;"></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;">由图3、图4<span style="color: black;">能够</span>看出：全塑前端框架密度分布图为“人”字造型，并且与两侧横梁有连接，拓扑优化后结果满足性能指标，<span style="color: black;">第1</span>次拓扑优化的3D数据，全塑前端框架重量为4.517Kg。</p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><strong style="color: blue;">3.2 </strong><strong style="color: blue;">第二次拓扑优化分析结果</strong></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">思虑</span>到散热器进排气系统的影响，“人”字造型结构截面过大，<span style="color: black;">因此呢</span>，需进一步拓扑优化，一方面是为了最大程度的实现全塑前端框架的轻量化，另一方面是为了满足散热器的排气量。第二次拓扑优化是在<span style="color: black;">第1</span>次3D数据上直接进行的，<span style="color: black;">掌控</span><span style="color: black;">要求</span>、约束<span style="color: black;">要求</span>及<span style="color: black;">目的</span>方程与<span style="color: black;">第1</span>次拓扑优化相同。拓扑优化密度分布云图及3D数据结果如图5所示：</p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/lR4GOtoy9vL0ZZp6Aueia7n3h9Rb3ZuNXH4IoaYeCCY3JbTQZwAfibrjMKJNH369ric64Xlria0Hzn4uKDIiaoVaTDg/640?wx_fmt=png&tp=webp&wxfrom=5&wx_lazy=1&wx_co=1" style="width: 50%; margin-bottom: 20px;"></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/lR4GOtoy9vL0ZZp6Aueia7n3h9Rb3ZuNXAWh0RRicnHmCaIjgUgTgZ8cUMnuYzOTve5MI5SSiap1BI0PRCU8MkkcA/640?wx_fmt=gif&tp=webp&wxfrom=5&wx_lazy=1&wx_co=1" style="width: 50%; margin-bottom: 20px;"></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/lR4GOtoy9vL0ZZp6Aueia7n3h9Rb3ZuNXAWh0RRicnHmCaIjgUgTgZ8cUMnuYzOTve5MI5SSiap1BI0PRCU8MkkcA/640?wx_fmt=gif&tp=webp&wxfrom=5&wx_lazy=1&wx_co=1" style="width: 50%; margin-bottom: 20px;">拓扑优化后，锁扣刚度、锁扣强度、一阶模态如图6所示：</p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/lR4GOtoy9vL0ZZp6Aueia7n3h9Rb3ZuNXiaZ4Wu3F2QmJKmL3OM7pZh4yh6TvjNySwMc9LTYicvFoyI6zMdu1rVhw/640?wx_fmt=png&tp=webp&wxfrom=5&wx_lazy=1&wx_co=1" style="width: 50%; margin-bottom: 20px;"></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"> 由图5、图6<span style="color: black;">能够</span>看出：全塑前端框架密度分布图<span style="color: black;">一样</span>为“人”字造型，并且与两侧横梁有连接，拓扑优化后结果满足性能指标，第二次拓扑优化的3D数据，全塑前端框架重量为3.658Kg，同比<span style="color: black;">第1</span>次3D数据减轻19%，且满足散热器进排气量<span style="color: black;">需求</span>。</p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">-END-</span></p>
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