镁铝合金组装式车轮结构-材料-性能一体化轻量化多目标优化设计方法研究

Design a new lightweight wheel assembled by magnesium alloy rim and aluminium alloy spoke. Wheel load extraction methods are investigated. Structure-material- behavior integration lightweight design methods for an assembled wheel are established. Lightweight design scheme will be determined through optimization. Weight reduction effect more than 10% comparing with aluminium wheel will be obtained under the condition of satisfying strength, stiffness, fatigue, vibration characteristic and aerodynamic performance. Influence of spoke shape, amount and physical dimension on the aerodynamic and dissipation heat performance of the rotating wheel is clarified. Influencing regularities of structure and material parameters , and different process route on wheel lightweight and service performance are indicated. Effect regularity of connection modes between rim and spoke on service performance of the wheel is revealed. Through the above research, optimal connection mode and process route of assembled lightweight wheel are ascertained. Energy-saving mechanism and influence of lightweight wheels, which are unsprung mass and they move and rotate during running, on automotive fuel economy are investigated profoundly. Develop prototype of lightweight wheel and verify validity of optimization design results of assembled lightweight wheel. Lightweight design procedure of assembled wheel is built up. Basis and key science problems in development and design of the assembled wheel are solved.

设计一种由镁合金轮辋和铝合金轮辐组装式的新型轻量化车轮结构，研究车轮载荷的提取方法，建立组装式车轮结构-材料-综合性能一体化多目标轻量化优化设计方法，确定出车轮的轻量化优化设计方案，在保证车轮强度、刚度、疲劳寿命、振动特性和空气动力性能的条件下，与相同的铝合金车轮相比减重10%以上。弄清轮辐形状、条数和结构尺寸对车轮旋转时空气动力性和散热性能的影响特性，阐明车轮结构和材料特性参数以及轮辋和轮辐不同的加工工艺路径对车轮轻量化和性能影响的规律性，揭示轮辋和轮辐间的不同连接方式对车轮服役性能影响的规律性，确定组装式车轮的最佳工艺路径和连接方式，进一步研究作为非簧载质量的车轮这种移动和转动综合部件的轻量化对汽车燃料经济性的影响和节能机理，研制组装式轻量化车轮样件，试验验证组装式车轮轻量化优化设计结果的正确性，建立组装式车轮结构的轻量化设计流程，解决组装式新型车轮设计开发中的基础关键科学问题。

开发组装式混合材料高性能轻量化车轮，对提升整车的经济性、动力性、操纵性、舒适性、制动性能有重要意义。本项目设计研发出一款由镁合金轮辋和铝合金轮辐构成的新型组装式车轮，提出了基于多疲劳试验工况的联合拓扑优化方法，构建了组装式车轮结构-材料-性能-连接工艺一体化优化设计方法。建立了镁铝合金组装式车轮强度、刚度、疲劳性能、13°冲击和90°冲击性能的仿真分析流程，并建立了车轮综合性能评价方法和指标；分析了车轮结构尺寸参数对车轮弯曲和径向疲劳性能、冲击性能、空气动力学性能和传热性能的影响机制，建立了综合考虑车轮弯曲和径向疲劳、冲击和气动性能的联合优化设计模型，基于代理模型理论方法对组装式车轮进行了轻量化多学科、多目标优化设计，实现了车轮设计优化中基于多种性能指标的多学科耦合，通过对轻量化优化设计后的车轮进行模态、疲劳、冲击性能试验，验证了组装式车轮多目标多学科优化设计的有效性；建立了组装式车轮胶接、螺接、铆接、胶栓、粘铆复合连接有限元模型，研究了镁铝合金组装式车轮在胶接、螺接、铆接、胶螺、粘铆复合连接条件下车轮的疲劳耐久性，提出了车轮胶栓复合连接一体化轻量化多目标优化设计方法，并对车轮压铆、粘铆连接工艺进行了深入研究，为组装式混合材料车轮综合性能匹配和快速连接设计提供了新的思路和方法。. 本项目共发表学术论文6篇，其中SCI论文3篇，EI论文3篇；获国家发明专利2项、实用新型专利3项，申请国家发明专利1项已进入实质审查阶段；培养博士研究生2名、硕士研究生2名；获得中国商业联合会科技进步特等奖1项，完满完成了课题的研究任务、实 现了研究目标。