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Structure Performance Development and Optimization Design of All-Aluminum Frame
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Yifei Zhang, Chuang Lu, Yangyang Liao, Chuanpeng Ji, Rongrong Deng, Fengli Zhang
Automobile Technology & Material | 2026, (10) : 1 - 11
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Automobile Technology & Material | 2026, (10): 1-11
Structure Performance Development and Optimization Design of All-Aluminum Frame
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Yifei Zhang, Chuang Lu, Yangyang Liao, Chuanpeng Ji, Rongrong Deng, Fengli Zhang
Affiliations
  • BYD Auto Industry Co., Ltd., Shenzhen 518118
Published: 2026-10-20 doi: 10.19710/J.cnki.1003-8817.20260254
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To enhance both the crashworthiness and lightweight design of an all-aluminium frame, a multidisciplinary, performance-oriented development strategy was formulated. The methodology integrates functional zoning with material matching, enabling a region-specific development process that achieves an optimal trade-off between structural performance and mass efficiency. During the structural design phase, a topology optimisation approach based on the variable density method is implemented, with particular attention paid to energy-absorbing components and critical cast regions. This facilitated the resolution of conflicting performance requirements and the establishment of an optimal structural architecture. In the subsequent lightweight design phase, a parametric thickness optimisation technique is adopted to determine the most favourable distribution of material gauge across all functional zones. Under the precondition of satisfying requirements for strength, durability, Noise, Vibration and Harshness(NVH), as well as crash safety, the mass of the all-aluminium frame was reduced by 16.7%, corresponding to 7.5% of the total vehicle mass. The final design was subsequently validated through a comprehensive series of physical tests, and all performance indicators were confirmed to meet the predefined development targets.

All-aluminum frame  /  Lightweight  /  Topology optimization  /  Material thickness optimization
张逸飞, 卢闯, 廖扬扬, 纪传鹏, 邓容容, 张风利. 乘用车全铝车架结构性能开发与轻量化设计. 汽车工艺与材料, 2026 , (10) : 1 -11 . DOI: 10.19710/J.cnki.1003-8817.20260254
Yifei Zhang, Chuang Lu, Yangyang Liao, Chuanpeng Ji, Rongrong Deng, Fengli Zhang. Structure Performance Development and Optimization Design of All-Aluminum Frame[J]. Automobile Technology & Material, 2026 , (10) : 1 -11 . DOI: 10.19710/J.cnki.1003-8817.20260254
Year 2026 volume Issue 10
66
12
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doi: 10.19710/J.cnki.1003-8817.20260254
  • Online Date:2026-10-29
  • Published:2026-10-20
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    BYD Auto Industry Co., Ltd., Shenzhen 518118
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表12种不同金属材料的力学参数
科
Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)
属
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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