Article(id=1241408883126760294, tenantId=1146029695717560320, journalId=1227999626482147330, issueId=1241408875602178849, articleNumber=null, orderNo=null, doi=10.16579/j.issn.1001.9669.2025.08.018, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1698249600000, receivedDateStr=2023-10-26, revisedDate=1704816000000, revisedDateStr=2024-01-10, acceptedDate=null, acceptedDateStr=null, onlineDate=1773904541999, onlineDateStr=2026-03-19, pubDate=1755187200000, pubDateStr=2025-08-15, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1773904541999, onlineIssueDateStr=2026-03-19, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1773904541999, creator=13701087609, updateTime=1773904541999, updator=13701087609, issue=Issue{id=1241408875602178849, tenantId=1146029695717560320, journalId=1227999626482147330, year='2025', volume='47', issue='8', pageStart='1', pageEnd='174', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1773904540204, creator=13701087609, updateTime=1773904658798, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1241409373071798309, tenantId=1146029695717560320, journalId=1227999626482147330, issueId=1241408875602178849, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1241409373071798310, tenantId=1146029695717560320, journalId=1227999626482147330, issueId=1241408875602178849, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=149, endPage=158, ext={EN=ArticleExt(id=1241408887111349127, articleId=1241408883126760294, tenantId=1146029695717560320, journalId=1227999626482147330, language=EN, title=Strength simulation and topology optimization design of off-road vehicles’ hub motor housing, columnId=1240594158461703059, journalTitle=Journal of Mechanical Strength, columnName=Optimization·Reliability, runingTitle=null, highlight=null, articleAbstract=

Aiming at the issues of fracture and weight reduction in the wheel hub motor housing of an off-road vehicle, a structural strength finite element simulation analysis and structural topology optimization design were conducted. Firstly, a multi-body dynamics model of the entire vehicle was established, and a simulation analysis was performed to determine the load boundary conditions of the hub motor housing. Secondly, based on the spatial position relation between the housing and interconnected structures, a finite element model of the motor housing and suspension system was constructed for dynamic simulation analysis. Subsequently,using the OptiStruct software platform,with the objective of minimizing structural compliance and constraints on volume ratio before and after optimization as well as the maximum stress, a mathematical topology optimization model for the motor housing under various typical operating conditions was established and solved to obtain the optimal material distribution scheme. Finally, the optimization results were verified by simulation. The results indicate that compared to the existing design,the optimized hub motor housing structure experiences a stress reduction of over 40% and a weight reduction of 2.6%. It addresses the original fracture issue and eliminates the phenomenon stress concentration, thus providing the valuable reference for the design of similar hub motor housing structures.

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YANG Shu, E-mail:
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针对某越野车轮毂电机壳体断裂和减重问题,进行了结构强度有限元仿真分析和结构拓扑优化设计。首先,构建整车多体动力学模型,仿真分析确定轮毂电机壳体的载荷边界条件。其次,基于壳体与相连接结构的空间位置关系,建立电机壳体与悬架系统有限元模型,进行了动态仿真分析。随后,利用OptiStruct软件平台,以结构柔度最小化为目标,以优化前后体积比和最大应力为约束,建立电机壳体在多种典型工况下的拓扑优化数学模型,并求解得到最优材料分布方案。最后,对优化结果进行了仿真验证。结果表明,相比现有设计,优化后的轮毂电机壳体结构应力降低40%以上,质量减轻了2.6%,解决了原有的断裂问题,消除了应力集中现象,为类似结构的轮毂电机壳体设计提供了有益参考。

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杨姝,女,1978年生,辽宁大连人,博士,副教授;主要研究方向为结构拓扑优化研究;E-mail:
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亓昌,男,1978年生,陕西咸阳人,博士,教授,博士研究生导师;主要研究方向为车辆动力学与轻量化;E-mail:

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亓昌,男,1978年生,陕西咸阳人,博士,教授,博士研究生导师;主要研究方向为车辆动力学与轻量化;E-mail:

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亓昌,男,1978年生,陕西咸阳人,博士,教授,博士研究生导师;主要研究方向为车辆动力学与轻量化;E-mail:

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label=图11, caption=电机壳体拓扑优化模型, figureFileSmall=DD1a99k4upOqJlLanGy5eA==, figureFileBig=uDsAUOG+GL4LZMjv39aDZQ==, tableContent=null), ArticleFig(id=1241451349909500522, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=EN, label=Fig.12, caption=Topology optimization results of the motor housing, figureFileSmall=0gdAuYGPxT5irRIodTnRXg==, figureFileBig=TVRabjxTh0pJpAIO83a+Vg==, tableContent=null), ArticleFig(id=1241451351373312624, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=CN, label=图12, caption=电机壳体拓扑优化结果, figureFileSmall=0gdAuYGPxT5irRIodTnRXg==, figureFileBig=TVRabjxTh0pJpAIO83a+Vg==, tableContent=null), ArticleFig(id=1241451351507530360, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=EN, label=Fig.13, caption=Topology optimization of material distribution filtered with a relative density of 0.58, 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tableContent=null), ArticleFig(id=1241451351977292423, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=EN, label=Fig.15, caption=Stress distribution of the motor housing before and after optimization under the evading working condition, figureFileSmall=M1qjjVEvCljhUEQq+MGaWA==, figureFileBig=LtqDk9D5Z/m4rQGM99PGqQ==, tableContent=null), ArticleFig(id=1241451352090538632, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=CN, label=图15, caption=闪避工况下优化前后电机壳体应力分布, figureFileSmall=M1qjjVEvCljhUEQq+MGaWA==, figureFileBig=LtqDk9D5Z/m4rQGM99PGqQ==, tableContent=null), ArticleFig(id=1241451352212173454, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=EN, label=Fig.16, caption=Stress distribution of the motor housing before and after optimization under the trenching working condition, figureFileSmall=l5j1Y7+uuu+aluM9E6M46g==, figureFileBig=J4ShkRjJ469ImGlKWFg+xg==, tableContent=null), ArticleFig(id=1241451352325419667, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=CN, label=图16, caption=越壕工况下优化前后电机壳体应力分布, figureFileSmall=l5j1Y7+uuu+aluM9E6M46g==, figureFileBig=J4ShkRjJ469ImGlKWFg+xg==, tableContent=null), ArticleFig(id=1241451352505774743, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=EN, label=Fig.17, caption=Stress distribution of the motor housing before and after optimization under the wall-crossing condition, figureFileSmall=k+FukGZjvNz4/dLqWf4Atg==, figureFileBig=BYe45lizPWY4mLCDXEsLWw==, tableContent=null), ArticleFig(id=1241451352602243738, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=CN, label=图17, caption=越墙工况下优化前后电机壳体应力分布, figureFileSmall=k+FukGZjvNz4/dLqWf4Atg==, figureFileBig=BYe45lizPWY4mLCDXEsLWw==, tableContent=null), 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tableContent=null), ArticleFig(id=1241451353084588711, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=CN, label=图19, caption=垂直落地工况下优化前后电机壳体应力分布, figureFileSmall=Z1ETbOGAWWPcPagt6QiWkA==, figureFileBig=FKMcuwjsJ9eKkP7hTdUrIg==, tableContent=null), ArticleFig(id=1241451353160086188, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=EN, label=Fig.20, caption=Stress distribution of dynamic simulation of the motor housing after optimization under typical working conditions, figureFileSmall=otz0RdQi5lva1ExuYhXZtw==, figureFileBig=6gJTuuACdmcDqniPcamzNg==, tableContent=null), ArticleFig(id=1241451353260749487, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=CN, label=图20, caption=典型工况下优化后的电机壳体动态仿真应力分布, figureFileSmall=otz0RdQi5lva1ExuYhXZtw==, figureFileBig=6gJTuuACdmcDqniPcamzNg==, tableContent=null), ArticleFig(id=1241451353378190002, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=EN, label=Tab.1, caption=

Material cards and parameter settings used in finite element simulation

, figureFileSmall=null, figureFileBig=null, tableContent=
材料MaterialLs-Dyna中材料卡片及对应材料参数设置
Material card and corresponding material parameter settings in Ls-Dyna
42CrMo结构钢
42CrMo structural steel
密度Density
7 850 kg/m3
弹性模量
Modulus of elasticity
210 GPa
泊松比
Poisson ratio
0.3
屈服强度
Yield strength
920 MPa
失效伸长率
Failure elongation
0.12
材料卡片
Material card
MATL24
橡胶Rubber密度Density
1 270 kg/m3
剪切模量
Shear modulus
48 MPa
材料卡片
Material card
MATL7
刚体Rigid body密度Density
7 850 kg/m3
弹性模量
Modulus of elasticity
210 GPa
泊松比
Poisson ratio
0.3
材料卡片
Material card
MATL20
弹簧Spring刚度Stiffness
250 N/mm
材料卡片
Material card
SDMAT1
阻尼Damping阻尼系数
Damping coefficient
5
材料卡片
Material card
SDMAT2
), ArticleFig(id=1241451353483047603, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=CN, label=表1, caption=

有限元仿真所用材料卡片及参数设置

, figureFileSmall=null, figureFileBig=null, tableContent=
材料MaterialLs-Dyna中材料卡片及对应材料参数设置
Material card and corresponding material parameter settings in Ls-Dyna
42CrMo结构钢
42CrMo structural steel
密度Density
7 850 kg/m3
弹性模量
Modulus of elasticity
210 GPa
泊松比
Poisson ratio
0.3
屈服强度
Yield strength
920 MPa
失效伸长率
Failure elongation
0.12
材料卡片
Material card
MATL24
橡胶Rubber密度Density
1 270 kg/m3
剪切模量
Shear modulus
48 MPa
材料卡片
Material card
MATL7
刚体Rigid body密度Density
7 850 kg/m3
弹性模量
Modulus of elasticity
210 GPa
泊松比
Poisson ratio
0.3
材料卡片
Material card
MATL20
弹簧Spring刚度Stiffness
250 N/mm
材料卡片
Material card
SDMAT1
阻尼Damping阻尼系数
Damping coefficient
5
材料卡片
Material card
SDMAT2
), ArticleFig(id=1241451353629848247, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=EN, label=Tab.2, caption=

Comparison of maximum and minimum principal strain at testing points of the motor housing

, figureFileSmall=null, figureFileBig=null, tableContent=
工况
Working condition
测试工况最大主应变最大值
Maximum principal strain under testing conditions/10-6
仿真工况最大主应变最大值
Maximum principal strain under simulation conditions/10-6
误差
Error/%
测试工况最小主应变最小值
Minimum principal strain under testing conditions/10-6
仿真工况最小主应变最小值
Minimum principal strain under simulaion conditions/10-6
误差
Error/%
越0.4 m垂直墙(测试)
Over 0.4 m vertical wall (test)
805.14-127.18
越0.8 m垂直墙(测试及仿真)
Over 0.8 m vertical wall (test and simulation)
987.821 068.828.2-239.58-262.589.6
越1.4 m壕沟(测试及仿真)
Over 1.4m trench crossing (test and simulation)
1 158.451 105.164.6-393.33-352.0110.5
车轮撞击0.1 m障碍物(测试及仿真)
Wheel impact on 0.1 m obstacle (test and simulation)
1 045.311 147.739.8-285.16-316.8111.1
爬升35°坡道(测试)Climb 35° ramp (test)649.04-90.76
垂直落地(仿真)Vertical landing (simulation)1 175.64-407.83
), ArticleFig(id=1241451353730511546, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=CN, label=表2, caption=

电机壳体测点处最大及最小主应变对比

, figureFileSmall=null, figureFileBig=null, tableContent=
工况
Working condition
测试工况最大主应变最大值
Maximum principal strain under testing conditions/10-6
仿真工况最大主应变最大值
Maximum principal strain under simulation conditions/10-6
误差
Error/%
测试工况最小主应变最小值
Minimum principal strain under testing conditions/10-6
仿真工况最小主应变最小值
Minimum principal strain under simulaion conditions/10-6
误差
Error/%
越0.4 m垂直墙(测试)
Over 0.4 m vertical wall (test)
805.14-127.18
越0.8 m垂直墙(测试及仿真)
Over 0.8 m vertical wall (test and simulation)
987.821 068.828.2-239.58-262.589.6
越1.4 m壕沟(测试及仿真)
Over 1.4m trench crossing (test and simulation)
1 158.451 105.164.6-393.33-352.0110.5
车轮撞击0.1 m障碍物(测试及仿真)
Wheel impact on 0.1 m obstacle (test and simulation)
1 045.311 147.739.8-285.16-316.8111.1
爬升35°坡道(测试)Climb 35° ramp (test)649.04-90.76
垂直落地(仿真)Vertical landing (simulation)1 175.64-407.83
), ArticleFig(id=1241451353843757758, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=EN, label=Tab.3, caption=

Maximum load at the hub center under typical working conditions

, figureFileSmall=null, figureFileBig=null, tableContent=
典型工况
Typical working condition
轮毂中心X方向
载荷
X-direction load of the hub center/N
轮毂中心Y
向载荷
Y-direction load of the hub center/N
轮毂中心Z
向载荷
Z-direction load of the hub center/N
闪避Evading-1 437.51 7501 783
越壕
Trench-crossing
9 0636014 222
越墙
Wall-crossing
7 714.5232.58 353.6
冲击Impact-1 154.5-41 839
垂直落地
Vertical landing
5 897129 455.9
), ArticleFig(id=1241451353940226750, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=CN, label=表3, caption=

典型工况下轮毂中心处最大载荷值

, figureFileSmall=null, figureFileBig=null, tableContent=
典型工况
Typical working condition
轮毂中心X方向
载荷
X-direction load of the hub center/N
轮毂中心Y
向载荷
Y-direction load of the hub center/N
轮毂中心Z
向载荷
Z-direction load of the hub center/N
闪避Evading-1 437.51 7501 783
越壕
Trench-crossing
9 0636014 222
越墙
Wall-crossing
7 714.5232.58 353.6
冲击Impact-1 154.5-41 839
垂直落地
Vertical landing
5 897129 455.9
), ArticleFig(id=1241451354024112833, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=EN, label=Tab.4, caption=

Equivalent static load application under five typical working conditions

, figureFileSmall=null, figureFileBig=null, tableContent=
典型工况
Typical working condition
载荷施加方向
Direction of load application
轮毂中心载荷
Load at the hub center/N
悬架弹簧连接处载荷
Load at the suspension spring joint/N
车体连接处载荷
Load at the body joint/N
闪避
Evading
X-1 437.5-1 9433 457.7
Y1 7500-1859
Z1 783-5 434.84 799.6
越壕
Trench-crossing
X9 063-8 6892 911
Y600-37
Z14 22224 1468 954
越墙
Wall-crossing
X7 714.5-4 609.3-11 840.7
Y232.501 769
Z8 353.6-12 804-4 622.3
冲击
Impact
X-1 154.5-10 401.92 460.8
Y-4026.8
Z1 839-30 663.819 209.9
垂直落地
Vertical landing
X5 8978 6037 326
Y-1202
Z9 455.923 14113 284
), ArticleFig(id=1241451354116387524, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=CN, label=表4, caption=

5种典型工况下等效静态载荷施加情况

, figureFileSmall=null, figureFileBig=null, tableContent=
典型工况
Typical working condition
载荷施加方向
Direction of load application
轮毂中心载荷
Load at the hub center/N
悬架弹簧连接处载荷
Load at the suspension spring joint/N
车体连接处载荷
Load at the body joint/N
闪避
Evading
X-1 437.5-1 9433 457.7
Y1 7500-1859
Z1 783-5 434.84 799.6
越壕
Trench-crossing
X9 063-8 6892 911
Y600-37
Z14 22224 1468 954
越墙
Wall-crossing
X7 714.5-4 609.3-11 840.7
Y232.501 769
Z8 353.6-12 804-4 622.3
冲击
Impact
X-1 154.5-10 401.92 460.8
Y-4026.8
Z1 839-30 663.819 209.9
垂直落地
Vertical landing
X5 8978 6037 326
Y-1202
Z9 455.923 14113 284
), ArticleFig(id=1241451354254799562, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=EN, label=Tab.5, caption=

Comparison of maximum stresses of the motor housing before and after optimization

, figureFileSmall=null, figureFileBig=null, tableContent=
典型工况
Typical working condition
优化前最大应力值
Maximum stress before optimization/MPa
优化后最大应力值
Maximum stress after optimization/MPa
最大应力减少比例
Maximum stress reduction ratio/%
闪避
Evading
64.733.548.2
越壕
Trench-crossing
165.781.850.6
越墙
Wall-crossing
112.468.039.5
冲击
Impact
267.3122.854.1
落地
Vertical landing
208.796.253.9
), ArticleFig(id=1241451354355462860, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241408883126760294, language=CN, label=表5, caption=

优化前后电机壳体最大应力值对比

, figureFileSmall=null, figureFileBig=null, tableContent=
典型工况
Typical working condition
优化前最大应力值
Maximum stress before optimization/MPa
优化后最大应力值
Maximum stress after optimization/MPa
最大应力减少比例
Maximum stress reduction ratio/%
闪避
Evading
64.733.548.2
越壕
Trench-crossing
165.781.850.6
越墙
Wall-crossing
112.468.039.5
冲击
Impact
267.3122.854.1
落地
Vertical landing
208.796.253.9
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越野车轮毂电机壳体强度仿真与拓扑优化设计
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亓昌 1 , 马远航 1 , 杨立宁 2 , 杨姝 1 , 王勃龙 1
机械强度 | 优化·可靠性 2025,47(8): 149-158
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机械强度 | 优化·可靠性 2025, 47(8): 149-158
越野车轮毂电机壳体强度仿真与拓扑优化设计
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亓昌1 , 马远航1, 杨立宁2, 杨姝1 , 王勃龙1
作者信息
  • 1.大连理工大学 汽车工程学院,大连 116024
  • 2.中国北方车辆研究所,北京 100072
  • 亓昌,男,1978年生,陕西咸阳人,博士,教授,博士研究生导师;主要研究方向为车辆动力学与轻量化;E-mail:

通讯作者:

杨姝,女,1978年生,辽宁大连人,博士,副教授;主要研究方向为结构拓扑优化研究;E-mail:
Strength simulation and topology optimization design of off-road vehicles’ hub motor housing
Chang QI1 , Yuanhang MA1, Lining YANG2, Shu YANG1 , Bolong WANG1
Affiliations
  • 1.School of Automotive Engineering, Dalian University of Technology, Dalian 116024, China
  • 2.China North Vehicle Research Institute, Beijing 100072, China
出版时间: 2025-08-15 doi: 10.16579/j.issn.1001.9669.2025.08.018
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针对某越野车轮毂电机壳体断裂和减重问题,进行了结构强度有限元仿真分析和结构拓扑优化设计。首先,构建整车多体动力学模型,仿真分析确定轮毂电机壳体的载荷边界条件。其次,基于壳体与相连接结构的空间位置关系,建立电机壳体与悬架系统有限元模型,进行了动态仿真分析。随后,利用OptiStruct软件平台,以结构柔度最小化为目标,以优化前后体积比和最大应力为约束,建立电机壳体在多种典型工况下的拓扑优化数学模型,并求解得到最优材料分布方案。最后,对优化结果进行了仿真验证。结果表明,相比现有设计,优化后的轮毂电机壳体结构应力降低40%以上,质量减轻了2.6%,解决了原有的断裂问题,消除了应力集中现象,为类似结构的轮毂电机壳体设计提供了有益参考。

越野车  /  轮毂电机壳体  /  有限元仿真  /  拓扑优化  /  轻量化设计

Aiming at the issues of fracture and weight reduction in the wheel hub motor housing of an off-road vehicle, a structural strength finite element simulation analysis and structural topology optimization design were conducted. Firstly, a multi-body dynamics model of the entire vehicle was established, and a simulation analysis was performed to determine the load boundary conditions of the hub motor housing. Secondly, based on the spatial position relation between the housing and interconnected structures, a finite element model of the motor housing and suspension system was constructed for dynamic simulation analysis. Subsequently,using the OptiStruct software platform,with the objective of minimizing structural compliance and constraints on volume ratio before and after optimization as well as the maximum stress, a mathematical topology optimization model for the motor housing under various typical operating conditions was established and solved to obtain the optimal material distribution scheme. Finally, the optimization results were verified by simulation. The results indicate that compared to the existing design,the optimized hub motor housing structure experiences a stress reduction of over 40% and a weight reduction of 2.6%. It addresses the original fracture issue and eliminates the phenomenon stress concentration, thus providing the valuable reference for the design of similar hub motor housing structures.

Off-road vehicle  /  Hub motor housing  /  Finite element simulation  /  Topology optimization  /  Lightweight design
亓昌, 马远航, 杨立宁, 杨姝, 王勃龙. 越野车轮毂电机壳体强度仿真与拓扑优化设计. 机械强度, 2025 , 47 (8) : 149 -158 . DOI: 10.16579/j.issn.1001.9669.2025.08.018
Chang QI, Yuanhang MA, Lining YANG, Shu YANG, Bolong WANG. Strength simulation and topology optimization design of off-road vehicles’ hub motor housing[J]. Journal of Mechanical Strength, 2025 , 47 (8) : 149 -158 . DOI: 10.16579/j.issn.1001.9669.2025.08.018
轮毂电机驱动系统是混合式电传动越野车的核心动力组件。它简化了驱动系统和整车结构,提供了更大的车内空间,并通过直接安装动力源在车轮内部以减少机械损失,提高了传动效率。电机壳体作为轮毂电机驱动系统的主要承载结构,对于抵抗各种复杂的机械载荷至关重要。服役过程中的冲击和疲劳载荷可能造成越野车轮毂电机壳体结构失效,可采用数值仿真技术分析结构刚度强度,进而对壳体结构进行优化设计。其中,利用拓扑优化技术设计轮毂电机壳体结构,通过优化材料的分布,不仅能够提高其刚度和强度等承载性能,还能有效减轻壳体结构质量,有利于整车轻量化。
围绕车辆轮毂电机壳体强度分析与结构优化,国内外学者已进行了相关研究。在电机壳体强度分析方面,董宏升[1]针对某电机壳体进行了结构强度分析,以确保壳体的可靠性,并对拓扑优化后的电机壳体进行了强度分析验证。杨军等[2]针对某随动系统电机壳体进行了不同方向冲击载荷下的强度仿真分析,并通过冲击试验验证。周成[3]针对某转向节式轮毂电机壳体进行车辆制动、侧滑、转向等工况下的强度仿真分析,为提高壳体强度和拓扑优化设计提供了指导。在轮毂电机壳体结构优化研究方面,CVETKOVSKI等[4]采用遗传算法对盘式永磁同步电机壳体进行了拓扑优化设计,实现了减重。为了改善车辆的垂向动力学性能,PROFUMO等[5-6]提出了轮毂电机、轮辋和轮毂零部件的一体化设计方法。陈遵友[7]针对轮毂电机转子支架结构进行了减重优化,根据结构特性将设计空间分为3个不同的设计域,在各设计域上进行了单独的拓扑优化设计。刘华年等[8]针对某轻型卡车的外转子轮毂电机壳体结构强度和内部电机的性能因素,开展了轮毂电机结构轻量化设计,并对优化后的电机性能进行了仿真分析,以满足设计要求。翟洪飞等[9]针对某电动汽车轮毂电机壳体结构的静动态特性,通过拓扑优化提高了壳体的刚度和固有频率,改善了局部应力集中现象,同时实现了轻量化目标。
现有的轮毂电机壳体强度分析,尤其是结构优化研究主要集中在乘用车轮毂电机壳体上,对于越野车轮毂电机结构优化设计的研究较为有限。此外,在结构拓扑优化研究中,获取准确的载荷边界条件存在一定困难,常用的载荷边界条件与实际工况接近程度不高,容易导致计算结果不准确和材料冗余的问题。
本文针对某型越野车轮毂电机壳体因结构强度不足,在实车道路测试中出现断裂的现象,开展了轮毂电机壳体结构的拓扑优化设计研究。首先,构建了车辆的多体动力学仿真模型,仿真获取了典型工况下轮毂电机壳体的准确载荷边界条件。其次,建立了轮毂电机壳体的有限元模型,基于载荷边界条件,得到了典型工况下电机壳体的应力分布情况。仿真结果表明,电机壳体应力集中的区域与实际断裂部位一致。最后,建立了电机壳体结构拓扑优化模型,求解得到了优化设计方案。针对优化前后的电机壳体进行了对比验证。本研究为越野车轮毂电机壳体的强度分析和减重设计提供了参考,有助于提升整车的安全性和轻量化水平。
针对图1中的某型军用越野车进行了一系列实车道路测试,包括越过0.4 m高的垂直墙、越过0.8 m高的垂直墙、越过1.4 m深的壕沟、车轮撞击0.1 m高障碍物、爬升35°坡道,以及在不同等级路面上的道路测试。主要的测试关注点包括各桥悬架弹簧的安装位置、轮毂电机壳体吊耳位置、轮毂电机壳体与车辆连接孔的位置,以及吊耳与连接轴中间部分的应力和应变。测试主要采用三角应变片,其粘贴方向包括竖直方向、水平方向和45°角方向,具体示意如图2所示。应变片使用胶水进行粘贴,其工作温度范围为-40~120 ℃。实车道路测试场地如图3所示。测试过程中发生了轮毂电机壳体断裂情况,如图4所示。
为了获取图1所示越野车在不同工况下轮毂电机壳体的载荷情况,并为结构优化设计提供准确的载荷边界条件,本研究结合多体动力学理论,首先构建了该越野车的多体动力学模型。
在构建整车系统仿真模型时,利用多体动力学仿真环境Recurdyn,系统中的构件以及地面活构件之间通过运动副连接。在只考虑完整约束的前提下,这些运动副可用系统广义坐标的代数方程表示[10]。由nb个刚性构件组成的系统广义坐标数nc=3×nb,则系统的广义坐标矢量可表示为
式中,q为系统广义坐标列向量。
系统广义坐标矢量表示的运动学约束方程组为
式中,nh为运动副的约束方程数;t为时间。
在运动学分析中,为确保系统有确定的运动,需要将系统的实际自由度降至零,可施加与自由度数量(nc-nh)相等的驱动约束,即
式(2)所示的系统运动学约束与式(3)所示的驱动约束相结合,形成了系统的总约束,为
对式(4)进行求导,得到速度约束方程为
对式(5)进行求导,得到加速度约束方程为
式中,矩阵ΦqΦqtΦtt均为雅可比矩阵。
以每个刚体的连体坐标系相对于惯性坐标系的位置和欧拉角作为广义坐标,即
系统中刚体之间通过运动副连接,运动副方程可用系统的广义坐标表达为非线性代数方程。利用拉格朗日乘子法建立多体系统的动力学方程为
式中,T为系统动能;Q为系统广义力列向量;λ为对应约束的拉格朗日乘子列向量。
基于上述理论,在多体动力学仿真环境Recurdyn中构建了图1中越野车轮毂电机及悬架系统的多体动力学模型,如图5所示。其中,前轮悬架模型包括电机壳体、限位块、导向杆、悬架弹簧等组件,如图5(a)所示。转向轮悬架模型包括电机壳体,上、下横臂、悬架弹簧和导向杆等;两横臂均与车身和电机壳体相连接,并可绕X轴转动;为实现转向功能,横臂与电机壳体连接处可绕Z轴转动,如图5(b)所示。通过Recurdyn Tire模块建立轮胎简化模型,并设置相应的轮胎模型参数。由于车身几何外形对多体动力学仿真结果没有影响,在确保车身质量、质心位置和惯量与实车参数一致的前提下,简化了车身外形,并构建了如图6所示的越野车整车多体动力学模型。
为获取越野车服役过程中轮毂电机壳体所受的载荷边界条件,选择5种典型的恶劣工况进行整车多体动力学仿真,包括闪避、越壕、越墙、冲击和垂直落地。闪避工况模拟越野车在行驶过程中快速避开前方障碍物的情景;越壕工况模拟越野车跨越高度为0.8 m、宽度为1.4 m的壕沟的情景;越墙工况模拟越野车翻越0.8 m高墙体的情景;冲击工况模拟越野车在快速行驶时,前轮撞到0.1 m高障碍物的情景;垂直落地工况模拟越野车从2 m高空由其他载具卸下后垂直落地的情景。通过Recurdyn仿真环境建立各典型工况对应的路面条件,设置车辆的速度和加速度参数,进行上述5种工况下的整车多体动力学仿真分析,如图7所示。
以前轮轮毂为例,基于整车多体动力学仿真结果,获取越壕、越墙、冲击和垂直落地4种典型工况下轮毂中心处Z方向的位移-时间曲线,如图8所示。将其作为电机壳体有限元仿真分析模型的载荷输入,本文所建电机壳体有限元仿真分析模型仅需输入Z方向位移-时间载荷曲线,便可求解出电机壳体在实际服役过程中的应力-应变情况。
基于电机壳体在整车中的安装位置和典型工况下的运动情况,建立电机壳体的有限元仿真分析模型。首先,创建车体连接件并将其设为刚体,约束其全部自由度,并通过转动副单元Revolute与轮毂电机壳体连接轴的中心点相连;采用特征尺寸为5 mm的四面体单元对车体连接件进行网格划分,同时采用特征尺寸为4、8 mm的四面体单元分别对电机壳体的纵臂部分和轮毂部分进行网格划分;轮毂电机壳体的吊耳位置通过RBE2单元与悬架弹簧和阻尼单元相连,并通过Ls-Dyna软件中的ELEMENT_DISCRETE关键字定义;保留连接处Y方向的转动自由度,约束悬架上支点全部自由度。其次,考虑电机壳体向上摆动高度的限制,添加橡胶限位块和限位装置,采用特征尺寸为6 mm的六面体单元对限位装置进行网格划分,将限位装置设为刚体,约束其全部自由度;限位块与电机壳体之间采用共节点网格。最后,采用轮胎和地面的简化模型,模拟典型工况下轮胎与地面的碰撞情况,分别采用特征尺寸为6、10 mm的六面体单元对轮胎简化模型和地面简化模型进行网格划分。利用弹簧阻尼单元模拟轮胎的刚度和阻尼,并通过转动副单元Revolute将轮胎简化模型与轮毂中心相连。这种建模方法使得在地面中心施加Z方向位移载荷时,轮胎中心会产生与轮胎中心X方向位移大小相等的附加位移,从而提高仿真效率。
在Ls-Dyna软件平台中建立电机壳体有限元仿真分析模型,如图9所示。所用材料卡片类型及仿真所需参数如表1所示。
对越野车电机壳体在4种典型工况下的应力分布进行有限元动态仿真分析,结果如图10所示。图10(a)、(b)、(c)、(d)分别对应越壕、越墙、冲击和垂直落地4种工况下前轮轮毂电机壳体在某一时刻的应力分布。红色区域表示在该工况下由于应力集中达到材料屈服极限的区域。由图10可以明显观察到,悬架弹簧吊耳连接处与车体连接件之间的电机壳体均出现了明显的应力集中现象,表明该位置的材料强度不足,易发生断裂现象。
测试数据统计了不同工况下测点处的最大主应变和最小主应变,其中轮毂电机壳体吊耳与连接轴中间部分的测试结果及与仿真结果对比情况如表2所示。
对比仿真结果中电机壳体在实际服役中的断裂情况,发现两者位置一致。同时,对比越0.8 m垂直墙、越1.4 m壕沟以及车轮撞击0.1 m障碍物的测试工况与仿真工况的最大主应变最大值和最小主应变最小值,发现误差均在10%左右,最高为11.1%。这表明仿真结果的可信度较高,证明了有限元建模方法的正确性,也说明电机壳体的材料分布不够合理。
有限元仿真结果和实际服役过程中的断裂情况均显示出电机壳体的结构强度存在明显不足。其主要原因如下:悬架与电机壳体连接部位在严苛工况下承受了较大载荷;同时,尽管电机壳体与车体连接部位保持了一定的转动自由度,但在壳体快速摆动过程中,其与车体连接处也会产生较大载荷,导致2个受力点之间产生较大的弯矩,从而引发壳体断裂。为了增强壳体的承载能力,需要对壳体进行结构优化设计。为获得最优的材料分布,有必要对壳体的设计空间进行一定拓展,拓展后的设计空间应符合以下原则:壳体在空间上不会与其他部件发生运动干涉;保留初始结构的内部电缆通道、轮毂安装位置以及与车体的连接轴。
结构拓扑优化基于数值仿真分析方法,将结构性能的被动校核转变为主动优化,利用材料在设计空间中不同区域的集中或分散,寻找最佳材料分布形式或传力路径,从而实现结构性能优化或减重[11]。常用的拓扑优化方法包括均匀化法、变密度法、渐进结构优化法等[12-14]。本文采用变密度法对电机壳体结构进行拓扑优化,其基本思想是假设材料具有可变的相对密度,范围在0~1,拓扑优化变量是经离散化的单元相对密度。其具体表达式为
式中,xi为拓扑优化设计变量;为各单元的材料初始密度;ρi为优化后的单元相对密度;相对密度为0表示该单元处无材料分布,相对密度为1表示单元密度等于材料初始密度,即材料实际存在。
连续体拓扑优化常引入固体各向同性材料惩罚模型(Solid Isotropic Material with Penalization, SIMP)的惩罚因子P,使相对密度在0.5附近的单元密度趋近于0或1,从而得到工程上可行的连续体结构[15]。假设材料的宏观弹性模量与其相对密度存在非线性关系,拓扑优化可转化为结构材料最优分布的研究,即
式中,E0为实体处的弹性模量(相对密度为1);Emin为孔洞处的弹性模量(相对密度为0);为带有惩罚因子P的设计变量。通常Emin=E0/1000以保证结果的收敛性。
轮毂电机壳体拓扑优化设计考虑了越野车的5种典型工况,即闪避、越壕、越墙、冲击和垂直落地。通过多体动力学仿真确定了这些典型工况下壳体的载荷边界条件。针对拓展设计空间后的电机壳体,建立了多工况下的拓扑优化有限元模型,并将轮毂与轮胎的安装部位、内部电缆通道以及与车体连接轴等区域划分为非设计域,如图11所示。在模型中,引入了弹簧单元,并限制了弹簧与车体连接点的X、Y、Z这3个方向的平动自由度,以及X、Z方向的转动自由度。同时,对与车体连接件相连的转动轴,限制了其X、Y、Z这3个方向的平动自由度以及X、Z方向的转动自由度。
表3列出了5种工况下轮毂中心的最大载荷情况。在拓扑优化模型中,5种工况的权重系数均设定为0.2。
拓扑优化目标为5种工况下电机壳体加权柔度最小,优化后的壳体体积为优化前的90%,优化后的结构应力不超过310 MPa(材料屈服强度为920 MPa,安全系数为3)。建立考虑5种工况的电机壳体结构拓扑优化数学模型为
式中,Cj为工况j下壳体结构柔度;wj为第j个工况的权重系数;V(ρ)为优化后的壳体体积;V(ρ0)为原壳体体积;σmax为结构应力最大值;σ为应力约束值;K为结构刚度矩阵;U为位移向量;F为载荷向量;NE为单元总个数。
电机壳体的拓扑优化结果如图12所示。图12中,红色区域代表相对密度接近1的设计单元,蓝色区域则代表相对密度趋近0的设计单元,材料分布勾勒出清晰的传力路径。引入惩罚因子后,能够有效地使拓扑优化设计变量值趋于0或1,减少了中间密度单元的数量。选择相对密度阈值0.58,对设计单元进行过滤,得到如图13所示的清晰且连续的材料最佳分布。与现有设计相比,优化后的结构不仅保留了壳体的安装和连接位置,还在原设计的断裂处分布了更多的材料,有效提升了壳体与悬架连接处的结构承载性能。基于拓扑优化结果,同时考虑内部电缆的密封和悬架弹簧的安装情况,构建优化后的轮毂电机壳体几何模型,如图14所示。
基于多体动力学仿真所获得的5种典型工况载荷边界条件,对经过优化的电机壳体和现有设计进行仿真对比验证。
采用惯性释放法以平衡惯性力,在轮毂中心、电机壳体与悬架弹簧及车体连接处分别施加典型工况下X、Y、Z这3个方向的等效静态载荷,具体数值如表4所示。
仿真求解得到5种工况下优化前后电机壳体的材料应力分布情况,如图15~图19所示。
仿真结果显示,现有设计中,各典型工况下电机壳体的应力主要集中在车体连接轴和吊耳之间的区域,这就是壳体实际发生断裂的位置。经过优化设计,电机壳体在吊耳处的结构更为合理,避免了现有设计中存在的小曲率圆角,从而在各工况受载时实现了应力分布的均匀化和应力数值的明显降低。具体而言,闪避工况下,壳体最大应力从64.7 MPa降低到33.5 MPa,减小了48.2%;越墙工况下,最大应力从112.4 MPa减少到68.0 MPa,减小了39.5%;越壕、冲击和落地工况下的最大应力分别从165.7、267.3、208.7 MPa分别减少到81.8、122.8、96.2 MPa,减少比例均超过50%。优化前后电机壳体最大应力数值的对比如表5所示。
对优化后的电机壳体在越壕和垂直落地工况下的应力分布进行动态仿真分析,结果如图20所示。与图10显示的现有设计仿真结果相比,可以明显观察到,在优化设计后,壳体结构能够更有效地发挥材料的承载能力,避免在恶劣工况下出现局部应力集中而导致壳体断裂。此外,优化设计后的壳体质量为18.1 kg,比现有设计的18.6 kg减重约2.6%。
基于越野车多体动力学仿真结果,进行了轮毂电机壳体强度仿真分析。在此基础上,提出了基于拓扑优化的设计方案,以解决壳体结构断裂和减重问题,得到如下主要结论:
1) 针对传统的结构强度仿真分析与拓扑优化研究中,载荷边界与实际工况不符导致的材料冗余和计算结果不准确的问题,构建了整车多体动力学仿真模型,能够精确获取轮毂电机壳体在典型工况下的载荷边界条件。
2) 对某轮毂电机壳体的强度仿真分析结果显示,仿真结果与实际服役过程中的断裂情况一致,从而验证了本文电机壳体及悬架有限元建模方法的正确性。所提出的方法可用于类似结构的强度仿真分析。
3) 优化设计后的轮毂电机壳体在典型工况下的应力减少40%以上,同时实现了减重2.6%,有效避免了局部应力集中现象,证实了优化设计方案的可行性。为类似结构轮毂电机壳体设计提供了有益参考。
  • 科技部高技术研究发展中心项目(2022YFB2503503)
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2025年第47卷第8期
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doi: 10.16579/j.issn.1001.9669.2025.08.018
  • 接收时间:2023-10-26
  • 首发时间:2026-03-19
  • 出版时间:2025-08-15
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  • 收稿日期:2023-10-26
  • 修回日期:2024-01-10
基金
Project of the High Tech Research and Development Center of Ministry of Science and Technology(2022YFB2503503)
科技部高技术研究发展中心项目(2022YFB2503503)
作者信息
    1.大连理工大学 汽车工程学院,大连 116024
    2.中国北方车辆研究所,北京 100072

通讯作者:

杨姝,女,1978年生,辽宁大连人,博士,副教授;主要研究方向为结构拓扑优化研究;E-mail:
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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