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摘要:
应用轻量化材料如高强度钢和铝、镁合金等来替代普通钢制造汽车承载构件已成为发展趋势。本文以工业铝合金为材料设计了一种新型的轻型城郊客车车架，并建立有限元模型进行了多种典型工况的仿真分析。首先，基于CATIA进行了客车车架各零部件的设计，整体装配与校核；然后，通过简化模型、模拟连接等，在ANSYS Workbench中建立了合理的车架-悬架有限元模型；最后，模拟客车满载弯曲、制动等5种典型工况施加载荷与边界条件，进行有限元仿真，仿真结果表明该铝合金车架能够满足各典型工况的强度和刚度性能要求。
Abstract:Lightweight materials such as high-strength steel, aluminum alloy or magnesium alloy applied as substitutions of plain steel to manufacture of bearing structures on vehicle have been an obvious tendency. Using industrial aluminum alloy as material, a new light bus frame was designed in this paper, and then finite element simulations under multiple typical conditions were implemented based on the reasonable finite element model. First, all the components of the frame were designed, assembled and checked in CATIA. Secondly, the frame-suspension finite element model was established in ANSYS Workbench after model simplification, connections simulation, etc. Finally, finite element simulations under totally five kinds of typical conditions such as full-load bending and emergency braking were accomplished, and the results indicate that the strength and stiffness of this new bus frame can satisfy the requirements of the typical conditions.
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Key words:
- lightweight /
- aluminum alloy /
- bus frame /
- structural design /
- finite element
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图 1 纵梁和横梁的截面形状和参数
Figure 1. Cross section shape and parameters of longitudinal beam and crossbeam
图 6 各工况的等效应力云图和总变形云图
Figure 6. Contours of equivalent stress and total deformation under various loading condition
表 1 车架总体参数
Table 1. General parameters of frame
mm 参数 数值 轴距 4 000 轮距 1 850 前悬 1 050 后悬 1 950 前悬架板簧长度 1 050 后悬架板簧长度 1 500 纵梁长度 7 400 横梁最大长度 2 000 
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表 2 Al 6061-T6/T651的材料参数
Table 2. Material parameters of Al 6061-T6/T651
参数 数值 密度/(kg·m-3) 2 700 弹性模量/GPa 68.95 剪切模量/GPa 26.0 泊松比 0.33 极限强度/MPa 310.3 屈服强度/MPa 276 抗剪强度/MPa 207
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表 3 车架中不同接触关系的主要设置
Table 3. Main setting of various connections on frame
装配关系 接触对象 接触类型 算法 间隙调整 焊接 线-面 绑定 多点约束法 忽略间隙与穿透 焊接 面-面 绑定 罚函数法 调至恰好接触 摩擦接触 线-面，面-面 粗糙 增强拉格朗日法 调至恰好接触 固定 线-面 绑定 多点约束法 忽略间隙与穿透
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表 4 车架承受的簧载质量
Table 4. Sprung mass loading on frame
载荷类型 质量/kg 发动机总成 335 车身、驾驶室及其附件 758 动力总成 254 满座乘员、座椅及地板 1 325 油箱及油 135 水箱及水 110 行李舱 230 车架自重 371.2
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表 5 各工况的等效应力和总变形量最大值
Table 5. Maximum equivalent stress and total deformation under various loading conditions
工况编号 实际工况 最大等效应力/MPa 最大总变形量/mm a 弯曲 129.21 6.294 b 弯扭联合 176.79 14.537 c 加速 131.19 6.943 d 紧急制动 159.61 5.114 e 紧急转弯 135.98 7.240
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