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Article(id=1154021705900086008, tenantId=1146029695717560320, journalId=1146120084050784272, issueId=1154021703362532078, articleNumber=null, orderNo=null, doi=10.19562/j.chinasae.qcgc.2024.12.019, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1716134400000, receivedDateStr=2024-05-20, revisedDate=1718553600000, revisedDateStr=2024-06-17, acceptedDate=null, acceptedDateStr=null, onlineDate=1753069815372, onlineDateStr=2025-07-21, pubDate=1735056000000, pubDateStr=2024-12-25, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1753069815372, onlineIssueDateStr=2025-07-21, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1753069815372, creator=13701087609, updateTime=1753069815372, updator=13701087609, issue=Issue{id=1154021703362532078, tenantId=1146029695717560320, journalId=1146120084050784272, year='2024', volume='46', issue='12', pageStart='2143', pageEnd='2354', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=0, articleOrder=1, issueType=-1, specialIssue=null, createTime=1753069814768, creator=13701087609, updateTime=1753074363847, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1154040783624724753, tenantId=1146029695717560320, journalId=1146120084050784272, issueId=1154021703362532078, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1154040783624724754, tenantId=1146029695717560320, journalId=1146120084050784272, issueId=1154021703362532078, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=2339, endPage=2354, ext={EN=ArticleExt(id=1154021706336293626, articleId=1154021705900086008, tenantId=1146029695717560320, journalId=1146120084050784272, language=EN, title=Research on Design of Hollow Rectangular Front Axle with Variable Cross-section and Vertical and Longitudinal Performance Under Working Conditions, columnId=1149809889280750125, journalTitle=Automotive Engineering, columnName=Selected Papers, runingTitle=null, highlight=null, articleAbstract=

The front axle manufactured through forging has large dimension，and the stress on it is complex. It is difficult to lightweight due to the limitation of the I-beam structure. In this paper，the design method of hollow front axle is given，and the hollow rectangular structure with variable cross-section and wall thickness and a combination of leaf spring seats are used to achieve lightweight and improve bending and torsion resistance. The influence of wall thickness at the kingpin hole on the strength of the fist is revealed，and the appropriate wall thickness range of the fist and the height and width coefficient of the plugging hole is given，by the vertical and longitudinal working conditions of the finite element mode. The 1：1 hollow front axle sample with an axle load of 5 t is produced by using seamless steel pipes，which is 10.75% lighter than the forged front axle. The variation law of vertical displacement and axial stress changes on the lower surface of the shaft and the stress distribution at the edge of the sealing hole on the outer end face of the fist are revealed through stiffness tests under vertical and longitudinal working conditions，as well as static strength and fatigue life tests under vertical working condition. The results show that the stiffness and static strength of the variable cross-section hollow rectangular front shaft meet industry standards，and the fatigue life under vertical working condition is much higher than industry standards. It is indicated that the variable cross-section hollow front axle can improve performance and achieve lightweight.

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汽车前轴的尺寸大、受力复杂，主要用锻造方法制造，受到工字形结构的限制难以轻量化。本文给出了空心汽车前轴的设计方法，采用变截面变壁厚的空心矩形结构和组合的钢板弹簧座，实现轻量化、改善抗弯扭性能。通过垂向及纵向工况有限元模拟揭示主销孔处壁厚对拳部强度的影响规律，给出拳部壁厚系数、封堵孔高度系数、封堵孔宽度系数的合适范围。选用无缝钢管试制出某轴荷5 t的空心前轴1∶1样件，较锻造前轴轻量10.75%。针对试制的空心前轴样件，进行了垂向、纵向的刚度试验以及垂向工况的静强度试验、疲劳试验，揭示了轴体下表面的垂向位移、轴向应力的变化，揭示了拳部外端面封堵孔边缘的应力分布。试验结果表明：变截面空心矩形前轴的刚度、静强度均符合行业标准，垂向工况的疲劳寿命远高于行业标准，在轻量化的同时改善了性能。

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王连东，教授，博士研究生导师，博士，E-mail：。
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1—横梁；2—弯脖；3—拳部；4—板簧座；5—封堵；4a—板簧座上盖；4b—板簧座下托。

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1—转向节套管；2—试验工装；3—转向节；4—封堵；5—转向横拉杆；6—推力轴承；7—转向节臂；8—钢板弹簧座上盖；9—前轴管件。

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1—主销；2—转向节；3—锁销；4—转向横拉杆；5—钢板弹簧座；5a—钢板弹簧座上盖；5b—钢板弹簧座下托；6—前轴管件；7—转向节臂；8—推力轴承。

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figureFileSmall=yFXLsFHjr/Co9xXlnEcZfw==, figureFileBig=cET1Lt4/Ba4mJWQKGm9n3Q==, tableContent=null), ArticleFig(id=1170311043147375288, tenantId=1146029695717560320, journalId=1146120084050784272, articleId=1154021705900086008, language=EN, label=null, caption=null, figureFileSmall=QARkuROqeT1xH08m98WJUw==, figureFileBig=A9/+0TyufpFIYE0l4rSCNw==, tableContent=null), ArticleFig(id=1170311043206095545, tenantId=1146029695717560320, journalId=1146120084050784272, articleId=1154021705900086008, language=CN, label=图21, caption=空心前轴疲劳试验, figureFileSmall=QARkuROqeT1xH08m98WJUw==, figureFileBig=A9/+0TyufpFIYE0l4rSCNw==, tableContent=null), ArticleFig(id=1170311043256427194, tenantId=1146029695717560320, journalId=1146120084050784272, articleId=1154021705900086008, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
A 1.2 1.3 1.4 1.5 1.6
t4/mm 15.00 16.25 17.50 18.75 20.50
h5/mm 58.0 55.0 50.0 50.0 44.5
b5/mm 45.0 40.0 40.0 38.0 33.5
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拳部相关尺寸参数

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A 1.2 1.3 1.4 1.5 1.6
t4/mm 15.00 16.25 17.50 18.75 20.50
h5/mm 58.0 55.0 50.0 50.0 44.5
b5/mm 45.0 40.0 40.0 38.0 33.5
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零件名称 前轴管件 其它 主销
材料 27Mn2 40Cr 20CrMo
密度ρ/（kg·m-3） 7 850 7 850 7 870
弹性模量E/MPa 2.009×105 2.090×105 2.100×105
泊松比μ 0.285 0.270 0.278
屈服极限σs/MPa 580 785 685
抗拉强度σb/MPa 647 980 885
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各零部件材料属性

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零件名称 前轴管件 其它 主销
材料 27Mn2 40Cr 20CrMo
密度ρ/（kg·m-3） 7 850 7 850 7 870
弹性模量E/MPa 2.009×105 2.090×105 2.100×105
泊松比μ 0.285 0.270 0.278
屈服极限σs/MPa 580 785 685
抗拉强度σb/MPa 647 980 885
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A 1.2 1.3 1.4 1.5 1.6
σmax/MPa 203.07 158.64 108.64 86.07 52.82
强度极限比率 25.27% 19.74% 13.52% 10.71% 6.57%
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封堵孔边缘测量点最大轴向应力

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A 1.2 1.3 1.4 1.5 1.6
σmax/MPa 203.07 158.64 108.64 86.07 52.82
强度极限比率 25.27% 19.74% 13.52% 10.71% 6.57%
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A 1.6 1.5 1.4 1.3 1.2
点i/MPa 2.71 10.73 13.70 37.02 73.40
点j/MPa 2.45 12.22 16.67 44.65 81.31
点k/MPa 8.06 16.24 22.30 46.45 81.52
点l/MPa 8.99 17.52 23.35 65.37 95.53
点m/MPa 8.47 14.84 39.22 45.99 61.39
点n/MPa 14.84 17.49 42.50 58.79 86.30
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拳部测量点剪应力

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A 1.6 1.5 1.4 1.3 1.2
点i/MPa 2.71 10.73 13.70 37.02 73.40
点j/MPa 2.45 12.22 16.67 44.65 81.31
点k/MPa 8.06 16.24 22.30 46.45 81.52
点l/MPa 8.99 17.52 23.35 65.37 95.53
点m/MPa 8.47 14.84 39.22 45.99 61.39
点n/MPa 14.84 17.49 42.50 58.79 86.30
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截面位置 项目 高度 宽度 壁厚
横梁中段 设计值/mm 115 93 12.5
实测值/mm 117.6 94.7 12.5
横梁中段两侧 设计值/mm 123 80 12.5
实测值/mm 124.2 78.5 12.5
弯脖中部 设计值/mm 95 100 12
实测值/mm 99.6 101.8 12.5
拳部主销孔 设计值/mm 93 88 20.5
实测值/mm 93.0 88.5 20.5
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空心矩形轴管横截面尺寸

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截面位置 项目 高度 宽度 壁厚
横梁中段 设计值/mm 115 93 12.5
实测值/mm 117.6 94.7 12.5
横梁中段两侧 设计值/mm 123 80 12.5
实测值/mm 124.2 78.5 12.5
弯脖中部 设计值/mm 95 100 12
实测值/mm 99.6 101.8 12.5
拳部主销孔 设计值/mm 93 88 20.5
实测值/mm 93.0 88.5 20.5
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试样切取位置 σs/MPa Rm条件/MPa Rm真实/MPa δ/%
横梁中部 528.5 639.5 801.29 25.3
板簧座处 457.5 629.5 817.09 29.8
左右弯脖 462.3 635.3 803.65 26.5
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压制成形后前轴管件拉伸力学性能

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试样切取位置 σs/MPa Rm条件/MPa Rm真实/MPa δ/%
横梁中部 528.5 639.5 801.29 25.3
板簧座处 457.5 629.5 817.09 29.8
左右弯脖 462.3 635.3 803.65 26.5
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点坐标 D1 D2 D3 D4
X/mm 0 -200 -310 -360
Y/mm -57.51 -57.46 -57.43 -47.46
点坐标 D5 D6 D8 D9
X/mm -460 -510 -765 -835
Y/mm -47.44 -47.42 -124.68 -157.88
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位移测量点的坐标

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X/mm 0 -200 -310 -360
Y/mm -57.51 -57.46 -57.43 -47.46
点坐标 D5 D6 D8 D9
X/mm -460 -510 -765 -835
Y/mm -47.44 -47.42 -124.68 -157.88
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点坐标 U1 U2 U3 D7
X/mm -360 -460 -820 -700
Y/mm 75.52 75.53 249.74 -46.30
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轴体上下表面新增测量点的坐标

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测量点 0°应变/µε 45°应变/µε 90°应变/µε
U1 -2 413.77 -935.37 259.00
U2 -2 341.82 -1 247.56 329.00
U3 -474.92 -31.27 337.90
D1 2 253.81 730.86 -662.31
D2 1 850.13 286.70 -1 072.31
D3 2 426.83 1 183.62 -283.39
D5 1 933.43 513.65 -708.00
D6 1 694.71 222.63 -1 037.18
D7 1 297.05 108.50 -1 128.74
D8 993.14 508.86 -206.43
D9 253.29 225.71 93.86
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轴体上下表面位移测量点的应变

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U2 -2 341.82 -1 247.56 329.00
U3 -474.92 -31.27 337.90
D1 2 253.81 730.86 -662.31
D2 1 850.13 286.70 -1 072.31
D3 2 426.83 1 183.62 -283.39
D5 1 933.43 513.65 -708.00
D6 1 694.71 222.63 -1 037.18
D7 1 297.05 108.50 -1 128.74
D8 993.14 508.86 -206.43
D9 253.29 225.71 93.86
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测量点 0°应变/µε 45°应变/µε 90°应变/µε
a -16.14 -8.10 -31.14
b -52.58 -140.00 12.00
c 45.43 -334.86 -423.71
d 307.29 -195.86 -226.14
e 294.00 129.14 -251.00
f 216.43 194.14 -259.00
g -14.00 199.14 -108.86
h -52.57 140.00 18.86
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拳部端面位移测量点的应变

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测量点 0°应变/µε 45°应变/µε 90°应变/µε
a -16.14 -8.10 -31.14
b -52.58 -140.00 12.00
c 45.43 -334.86 -423.71
d 307.29 -195.86 -226.14
e 294.00 129.14 -251.00
f 216.43 194.14 -259.00
g -14.00 199.14 -108.86
h -52.57 140.00 18.86
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测量点 a b c d
σ0°/MPa -5.471 -10.749 -16.472 52.817
σ90°/MPa -7.82 -0.65 -89.82 -30.58
测量点 e f g h
σ0°/MPa 48.426 31.18 -9.907 -10.32
σ90°/MPa -36.62 -43.15 -24.89 0.85
), ArticleFig(id=1170311044783153871, tenantId=1146029695717560320, journalId=1146120084050784272, articleId=1154021705900086008, language=CN, label=表11, caption=

拳部端面封堵孔边缘测量点应力值

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测量点 a b c d
σ0°/MPa -5.471 -10.749 -16.472 52.817
σ90°/MPa -7.82 -0.65 -89.82 -30.58
测量点 e f g h
σ0°/MPa 48.426 31.18 -9.907 -10.32
σ90°/MPa -36.62 -43.15 -24.89 0.85
), ArticleFig(id=1170311044850262736, tenantId=1146029695717560320, journalId=1146120084050784272, articleId=1154021705900086008, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
测量点 a b c d
模拟值/MPa -5.56 -10.94 -16.528 53.79
相对误差/% 1.57 1.82 0.34 1.84
测量点 e f g h
模拟值/MPa 48.921 32.36 -10.09 -10.03
相对误差/% 1.02 3.75 1.81 2.77
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前轴管件轴向应力试验值与模拟值对比

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测量点 a b c d
模拟值/MPa -5.56 -10.94 -16.528 53.79
相对误差/% 1.57 1.82 0.34 1.84
测量点 e f g h
模拟值/MPa 48.921 32.36 -10.09 -10.03
相对误差/% 1.02 3.75 1.81 2.77
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变截面空心矩形前轴的设计及垂向、纵向工况性能的研究*
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王连东 1, 2 , 李金蔚 1, 2 , 冯凯 1, 2 , 张宇 1, 2 , 田野 1, 2
汽车工程 | 精选论文 2024,46(12): 2339-2354
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汽车工程 | 精选论文 2024, 46(12): 2339-2354
变截面空心矩形前轴的设计及垂向、纵向工况性能的研究*
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王连东1, 2 , 李金蔚1, 2, 冯凯1, 2, 张宇1, 2, 田野1, 2
作者信息
  • 1. 燕山大学，河北省特种运载装备重点实验室，秦皇岛 066004
  • 2. 燕山大学车辆与能源学院，秦皇岛 066004

通讯作者:

王连东，教授，博士研究生导师，博士，E-mail：。
Research on Design of Hollow Rectangular Front Axle with Variable Cross-section and Vertical and Longitudinal Performance Under Working Conditions
Liandong Wang1, 2 , Jinyu Li1, 2, Kai Feng1, 2, Yu Zhang1, 2, Ye Tian1, 2
Affiliations
  • 1. Yanshan University，Hebei Key Laboratory of Special Delivery Equipment，Qinhuangdao 066004
  • 2. School of Vehicle and Energy，Yanshan University，Qinhuangdao 066004
出版时间: 2024-12-25 doi: 10.19562/j.chinasae.qcgc.2024.12.019
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摘要
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汽车前轴的尺寸大、受力复杂，主要用锻造方法制造，受到工字形结构的限制难以轻量化。本文给出了空心汽车前轴的设计方法，采用变截面变壁厚的空心矩形结构和组合的钢板弹簧座，实现轻量化、改善抗弯扭性能。通过垂向及纵向工况有限元模拟揭示主销孔处壁厚对拳部强度的影响规律，给出拳部壁厚系数、封堵孔高度系数、封堵孔宽度系数的合适范围。选用无缝钢管试制出某轴荷5 t的空心前轴1∶1样件，较锻造前轴轻量10.75%。针对试制的空心前轴样件，进行了垂向、纵向的刚度试验以及垂向工况的静强度试验、疲劳试验，揭示了轴体下表面的垂向位移、轴向应力的变化，揭示了拳部外端面封堵孔边缘的应力分布。试验结果表明：变截面空心矩形前轴的刚度、静强度均符合行业标准，垂向工况的疲劳寿命远高于行业标准，在轻量化的同时改善了性能。

空心矩形前轴  /  设计方法  /  强度刚度  /  疲劳寿命  /  台架试验

The front axle manufactured through forging has large dimension，and the stress on it is complex. It is difficult to lightweight due to the limitation of the I-beam structure. In this paper，the design method of hollow front axle is given，and the hollow rectangular structure with variable cross-section and wall thickness and a combination of leaf spring seats are used to achieve lightweight and improve bending and torsion resistance. The influence of wall thickness at the kingpin hole on the strength of the fist is revealed，and the appropriate wall thickness range of the fist and the height and width coefficient of the plugging hole is given，by the vertical and longitudinal working conditions of the finite element mode. The 1：1 hollow front axle sample with an axle load of 5 t is produced by using seamless steel pipes，which is 10.75% lighter than the forged front axle. The variation law of vertical displacement and axial stress changes on the lower surface of the shaft and the stress distribution at the edge of the sealing hole on the outer end face of the fist are revealed through stiffness tests under vertical and longitudinal working conditions，as well as static strength and fatigue life tests under vertical working condition. The results show that the stiffness and static strength of the variable cross-section hollow rectangular front shaft meet industry standards，and the fatigue life under vertical working condition is much higher than industry standards. It is indicated that the variable cross-section hollow front axle can improve performance and achieve lightweight.

hollow rectangular front axle  /  design method  /  strength stiffness  /  fatigue life  /  bench test
王连东, 李金蔚, 冯凯, 张宇, 田野. 变截面空心矩形前轴的设计及垂向、纵向工况性能的研究*. 汽车工程, 2024 , 46 (12) : 2339 -2354 . DOI: 10.19562/j.chinasae.qcgc.2024.12.019
Liandong Wang, Jinyu Li, Kai Feng, Yu Zhang, Ye Tian. Research on Design of Hollow Rectangular Front Axle with Variable Cross-section and Vertical and Longitudinal Performance Under Working Conditions[J]. Automotive Engineering, 2024 , 46 (12) : 2339 -2354 . DOI: 10.19562/j.chinasae.qcgc.2024.12.019
正文
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前言
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前轴作为转向桥的大尺寸关键零部件，在使用过程中受到来自路面的垂向冲击载荷、制动产生的纵向载荷及转弯或侧滑产生的侧向载荷，要求具有高的强度和刚度[1]。目前，前轴主要用锻造方法制造（图1），横梁中段为上下近似等宽的工字形结构，横梁两侧呈上宽下窄的工字形，较宽的上翼面直接做为板簧座。锻造工艺较为成熟，已广泛用于3.5~7 t的前轴，但工字形的结构抗弯扭性能尤其抗纵向弯扭不高，板簧座下边较窄的部位易发生断裂失效（图2（a）），弯脖处也是受力较大的危险截面，车辆制动时，由于惯性作用使汽车向前俯冲，前轴载荷突然变大导致前轴应力集中加剧，易使弯脖处产生剪切断裂（图2（b）），在保证高性能的前提下如何实现轻量化是难题。
Zhang等[2]利用ANSYS Workbench软件对锻造前轴的强度和疲劳寿命进行了分析，确定出危险区域位于横梁部位。王国权等[3]进一步证明前轴弯脖及横梁中部出现应力集中。孔德利等[4]进行了前轴在制动、动载工况下的有限元分析，结果表明最大轴向应力位于板簧座底部。王欢锐等[5]研究了某商用车前轴在垂直弯曲疲劳试验中的失效模式及失效位置的形貌，系统地分析了前轴失效的主要原因及机理。孙捷等[6]对某前轴左侧主销孔外侧的断裂进行了分析，发现主销孔断裂主要是由于长期受到交变应力以及集中应力的作用。李伟等[7]在前轴疲劳试验中发现拳头附近的弯脖处发生失效。
作为车辆底盘大尺寸部件，前轴质量轻量化有助于减轻车辆底盘的质量[8]。目前锻造前轴主要通过更换前轴产品材料[9-10]、修改前轴产品截面尺寸来减轻产品质量[11]，但轻量化效果不明显，轻量化后前轴弯脖部位性能偏低，疲劳寿命不足[12]。周智等[13]通过在横梁中部采用镂空工字结构达到轻量化，但镂空设计削弱了产品的刚度、易发生断裂失效，应用场景受到极大限制，且增加了制造的成本。
近年来，国内研究者正在探索用无缝钢管整体成形汽车前轴，取得一些宝贵经验。吴志强[14]提出了一种整体式前轴，横梁、弯脖采用等高等宽的空心矩形截面，桥体端部为实体拳部，减轻了产品质量，但拳部内腔存在折叠等成形质量问题，极易产生应力集中严重降低了前轴的疲劳寿命，且等截面的横梁结构很难与现有悬架总成匹配。燕山大学公开一种大落差空心矩形截面汽车前轴管件的成形方法[15]，无缝钢管端部加热后进行镦粗增厚、轴向补料弯曲得到大落差的弓形管坯，利用模具进行整体压制成形得到横梁、弯脖、拳头为变截面变壁厚结构，但横梁存在尺寸突变增加成形难度，且尚未进行验证。
本文给出空心汽车前轴的设计方法，选用无缝钢管试制出轴荷5 t的空心前轴1∶1样件，实现轻量化；在此基础上进行垂向、纵向刚度试验以及垂向工况静强度试验、疲劳寿命试验，检验空心矩形前轴的强度刚度，为工程应用奠定重要基础。
1 变截面空心矩形汽车前轴的结构设计
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1.1 汽车前轴设计方法
（1）前轴由变截面变壁厚的空心矩形轴管和组合的钢板板簧座组成，以实现轻量化、改善抗弯扭性能，如图3和图4所示。轴管的横梁、弯脖、拳部横截面均为空心矩形。板簧座由上盖及下托组成，上盖呈板凳状，下托呈带三角形镂空U形结构，上盖、下托通过竖壁卡装在横梁中部。
（2）横梁采用变截面等壁厚结构，满足轻量化。横梁中段为设计基准，其截面高h1、宽b1、壁厚t1，满足h1=（1.1~1.3）b1，同时保证垂向工况、纵向工况的抗弯扭强度和刚度；横梁中段两侧向上抬起高度H1，形成一级落差，其截面高h2略大于h1，宽度b2略小于b1，提高横梁处刚度，减小在垂向工况下的变形，壁厚t2等于t1。基于在保证横梁刚度符合标准要求后实现轻量化设计，确定初始管坯壁厚，横梁部位壁厚保持不变。
（3）弯脖处截面宽度增加、高度减小、壁厚不变，提高抗弯扭能力，其中部截面的高h3略小于h1，宽度b4略大于b1，壁厚t3等于t1。
（4）拳部采用变截面厚壁矩形筒，由内侧向端部总体呈高度不变、宽度逐渐收窄，主销孔处截面高为h4，宽度为b4，壁厚较横梁中段大幅增加以保证足够的抗剪切强度，且满足t4=At1；拳部端面存在矩形孔，满足高h5=Bh4，宽b5=Cb4，并用封堵焊接。A、B、C分别为拳部壁厚系数、封堵孔高度系数、封堵孔宽度系数，通过有限元模拟确定。
1.2 轴荷5 t变截面空心矩形汽车前轴结构设计
针对轴荷5 t的变截面空心矩形轴管，选取初始长度2 240 mm、外径 Φ121 mm、壁厚12.5 mm的27Mn2无缝钢管，弹性模量E为2.01×105 MPa、泊松比µ为0.285，屈服强度为381.57 MPa、条件抗拉强度为588.43 MPa、延伸率为28%。
空心前轴拳部主销孔处的壁厚t4决定主销孔处的前后侧壁厚及端部封堵孔的大小，直接影响拳部在垂向工况、纵向工况下的强度。结合前期生产实践，t4大于横梁中段壁厚t1的1.7倍时，无缝钢管整体成形时拳部内腔产生折叠（图5），严重时出现裂纹。
1.3 前轴管件垂向、纵向性能有限元分析
下文分别对以下前轴管件进行垂向工况、纵向工况有限元模拟，通过模拟结果揭示主销孔处的壁厚t4对拳部强度的影响规律，进而给出拳部壁厚系数A、封堵孔高度系数B、封堵孔宽度系数C的合适取值范围。
主销孔处的壁厚t4与主销孔前后侧的壁厚及封堵孔尺寸如表1所示。
1.3.1 垂向工况性能分析
（1）有限元模型建立
使用ABAQUS有限元分析软件对汽车前轴进行垂向工况性能模拟，垂向工况有限元模型如图6所示，建立迪卡尔直角坐标系OXYZ：原点位于横梁中段矩形截面中点，X轴平行于横梁中段轴线，正向指向右方；Y轴在铅直方向，正向指向上方；Z轴正向指向车辆行驶方向。
各部件材料属性如表2所示。前轴总成轮距为1 980 mm，簧距为820 mm；约束两侧试验工装沿Y、Z方向的平动和绕X、Y轴的转动。依据设计需要施加3.85倍额定轴荷，在单侧板簧座上托正上方垂向力施力点沿Y轴负方向施加F1 Y =94325 N的垂向力。
（2）前轴垂向工况轴向应力结果分析
为检验前轴管件拳部端面矩形封堵对产品端部强度的影响，在封堵孔边缘选取应力测量点。假想在封堵孔的外围绘制高度h′、宽度b′的矩形，选取矩形的顶点b、d、f、h及各边的中点a、c、e、g，如图7所示；测量轴向应力沿圆弧切线方向。从a点绕逆时针方向至b点，各测量点和矩形孔中心的连线与高度方向（y轴正向）的夹角分别由0°增加至270°。
将封堵孔边缘测量点的轴向应力绘在图8中，结果表明：①封堵孔边缘测量点由上侧至下侧，轴向应力由压应力逐渐转换为拉应力，最大轴向拉应力均位于封堵孔下边缘附近；②随主销孔处的壁厚增大，封堵孔边缘点的轴向应力逐渐增大（最大轴向拉应力值如表3所示）；③当拳部壁厚系数A≥1.4时，最大轴向应力不超过材料条件抗拉强度（588.43 MPa）的18.50%，而当A小于1.4时，最大轴向拉应力急剧增大。
通过模拟结果进一步可知：拳部壁厚的变化不影响前轴管件的最大轴向应力值，其位于横梁中段一级落差下表面，数值为515.43 MPa，相应的强度系数为6.06。
1.3.2 纵向工况性能分析
（1）有限元模型建立
纵向工况前轴总成如图9所示，模拟时在转向节轴臂处安装试验工装。约束两侧板簧座上表面沿Y、Z方向的平动和全部转动，在单侧负载下表面施力点沿Z轴负方向施加1.1倍满载轴荷，即F2z =26950 N的纵向力。
（2）纵向工况剪切应力结果分析
选取矩形封堵孔上侧顶点i、j，下侧顶点k、l，选取主销孔后侧（靠近横梁侧）内壁垂直于拳部轴线平面上侧点m及下侧点n。当拳部壁厚系数A分别为1.6、1.4和1.2时，封堵顶点及主销孔内壁后侧剪应力分布如图10所示；测量各选取点在位于垂直拳部轴线平面上的剪应力，结果如表4所示。
模拟结果表明：①当A≥1.4时，选取点处的最大剪应力不超过材料条件抗拉强度（588.43 MPa）的7.50%；②当A小于1.4时，选取点处的剪应力急剧增加，当A=1.2时，封堵孔下侧顶点l处的剪应力达到95.53 MPa，达到条件抗拉强度的16.23%，较A=1.4时的最大剪应力增加124.78%。
前轴管件实际装配时，主销孔与主销之间存在径向间隙，须通过锁销锁止，在受到纵向冲击力时的剪应力大于模拟值。结合垂向工况、纵向工况的拳部的强度模拟结果，为保证空心前轴拳部的强度，最终确定：拳部壁厚系数A=1.4~1.6，相应的拳部壁厚系数B=0.35~0.45、封堵孔高度系数C=0.30~0.40。
2 轴荷5 t变截面空心矩形汽车前轴的试制
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2.1 样件试制
针对轴荷5 t的变截面空心矩形轴管，选取初始长度2 240 mm、外径 Φ121 mm、壁厚12.5 mm的27Mn2无缝钢管，弹性模量E为2.01×105 MPa、泊松比µ为0.285，屈服强度为381.57 MPa、条件抗拉强度为588.43 MPa、延伸率为28%。
在三向液压机上先将管坯两端进行热态镦粗增厚，再进行轴向补料弯曲得到弓形圆截面管坯，最后用上下模、前后模进行压制成形，得到变截面变壁厚的空心轴管管件，如图11所示。
压制成形的管件进行机加工制得空心前轴，总长度为1 874 mm、一级落差H1=10 mm，拳部高93 mm，封堵孔高40 mm，宽35 mm，拳部轴线与水平线夹角为7°；焊接封堵及钢板弹簧座得到前轴产品样件如图12所示。平均质量为82.4 kg，较同等轴荷的锻造前轴质量92.3 kg，单件轻量9.9 kg，质量减轻了10.75%。
实测空心前轴各部分的截面尺寸、壁厚，结果如表5所示，基本达到设计要求，存在弹性回弹，需要后期修正。
2.2 样件拉伸试验
在压制成形后的空心轴管的横梁中部、横梁两端及弯脖分别切取拉伸试件（图13）进行单向拉伸试验，得到的力学性能指标如表6所示。由试验结果可知：成形后的前轴管件的屈服强度超过450 MPa，真实抗拉强度超过800 MPa，延伸率超过25%，具有较好的强度和韧性。
3 空心矩形前轴刚度试验
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3.1 试验用前轴总成
装配好的前轴总成包括空心矩形前轴、转向节、转向横拉杆、主销、锁销、推力轴承及相关连接螺栓等（图14）。
3.2 垂向工况刚度试验
垂直工况台架试验在中国汽车零部件质量检测中心（湖北）进行。试验台由液压伺服疲劳试验机、工作台、液压泵站、测控系统及操作台、工装等组成（图15）。疲劳试验机作动器最大试验力为300 kN，行程范围为75~225 mm，试验频率范围为0.01~30 Hz，位移测量显示值相对误差为0.5%。
在过前轴轴线的铅直纵截面的下表面上选取9个位移测量点（图16），其中D1点在下对称点，D2、D2'点分别位于横梁中段左右侧的过渡位置，D3点左侧一级落差过渡处，D5、D4'点分别位于左侧、右侧板簧座下托外侧两条肋板之间，D6'点靠近右侧板簧座下托外侧肋板，D8点在左侧弯脖中部，D9'点在右侧拳部里侧。
选取的位移测量点的OXYZ坐标见表7所示。
刚度试验时，在板簧座上盖上方垂向施加3.85倍额定轴荷，单侧垂向载荷94 325 N。试验的3根前轴位移测量点的垂直位移如图17所示。
试验结构表明：
（1）3根前轴的最大垂向位移均位于横梁中段对称点D1，分别为16.01、15.77、15.63 mm，刚度系数分别为11.78、11.96、12.07 kN/mm，较车桥行业内普遍采用的刚度系数9.8 kN/mm提高20%以上。
（2）垂向位移由拳部到横梁中段两侧呈近似线性增加，在横梁中段呈抛物线形缓慢增加。以01空心前轴为例，垂向位移由弯脖中部下表面点D8的3.66 mm线性增加至横梁左侧过渡处D3点的13.95 mm，然后缓慢增至对称点D1的16.01 mm。
3.3 垂向工况刚度试验和纵向工况刚度试验
进行纵向力刚度试验时，固定左右两侧的钢板弹簧座，通过试验工装的竖臂在左右转向节的下方等于车轮半径的位置分别施加纵向力，测量前轴的纵向位移，如图18所示。在试验中，两侧竖臂施加的纵向力为26 950 N，总和为额定轴荷5 t的1.1倍。通过试验，测得右侧拳部和弯脖中部的位移分别为3.29和2.63 mm，纵向刚度评价系数分别为16.38 和20.49 kN/mm，远大于较车桥行业内采用9.8 kN/mm。
当A=1.6时纵向工况有限元模拟拳部和弯脖中部沿行驶方向变形量分别为2.47和1.97 mm，与试验值相比误差均不超过25%。
4 空心前轴垂向工况强度、疲劳寿命试验
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4.1 静强度试验
4.1.1 选取特征点粘贴应变片
（1）在空心前轴左侧轴体的上下表面选取11个应变测量点。除刚度试验时选取的点D1、D2、D3、D4、D5、D6、D9，增加4个点：弯脖下侧圆角区的外侧点D7，拳部主销孔内侧的上表面点U3，板簧座上盖两侧点U1、U2，如图19所示。新增的测量点坐标如表8所示。在选取的应变测量点上粘贴应变花，其中0°方向沿表面的轴线方向，90°方向沿前后方向（即Z向）。
（2）参照模拟时的测量点选取方法，在拳部外端圆弧面上假想矩形高度h′=50 mm、宽度b′=40 mm，选取矩形的顶点b、d、f、h及各边的中点a、c、e、g，粘贴应变花，其中0°方向沿圆弧的切线方向，90°方向平行主销孔轴线。
4.1.2 应变测量
测量前轴在3.85倍额定轴荷作用下的变形，轴体上下表面位移测量点的结果如表9所示，拳部外端面上的结果见表10所示。
4.1.3 应力计算及分析
由于垂直于应变花粘贴平面的方向无应力，由应变花0°及90°方向的正应变ε0°、ε90°，根据广义胡克定律便可计算出0°及90°方向的正应力σ0°、σ90°。
σ 0 ° = E 1 - μ 2 ε x + μ ε z
σ 90 ° = E 1 - μ 2 ε z + μ ε x
式中：E为弹性模量；μ为泊松比；ε为轴向应变。
由轴体上下表面的应力结果可知：
（1）轴体下表面轴线方向的拉应力高值区位于横梁中段及左右两侧的过渡处，如图20所示。横梁一级落差处D3点处的应力最大，其值为512.95 MPa；横梁中段对称点D1的应力为451.66 MPa，较D3点应力低11.95%。D3点、D1点的静强度系数分别为6.13、6.83，均大于车桥行业内普遍采用认可的静强度系数6。
（2）轴体下表面Z轴向的应力以压应力为主，最大压应力值-165.70 MPa，位于弯脖中部的D7点；在横梁一级落差处D3点，Z向应力为拉应力，其值为89.24 MPa。
（3）板簧上盖两侧点U1、U2的轴线方向的压应力分别为-511.08、-495.70 MPa，主销孔内侧U3的轴向压应力为-82.25 MPa。
由拳部端面封堵孔边缘测量点应力结果（表11）可知：封堵孔上边缘的点a、b、h的应力均很小，最大的应力10.75 MPa；封堵孔中部点c、g处，切线、高度方向的应力均为压应力，最大值为89.82 MPa，占真实抗拉强度（803.65 MPa）的11.18%；在封堵孔下边缘点e、d、 f处，切线方向的拉应力数值相对较大，最大值为52.82 MPa，仅占真实抗拉强度（803.65 MPa）的6.57%，对强度几乎无影响。
依据拳部壁厚系数A取1.6试制的试验管件，拳部端面测量点轴向应力模拟值与试验值对比如表12所示，最大误差不超过4%。
4.2 疲劳寿命试验
针对刚度试验后的3根前轴进行垂向工况疲劳试验，动载荷施加范围为0.5~3.0倍额定轴荷，载荷波形为余弦波，振动频率为5 Hz，如图21所示。
第1根前轴，额定轴荷按5 t计，单侧板簧座上施加的最大、最小垂向载荷分别为73 500、12 250 N，疲劳寿命达到145.17万次时未出现失效，相比于行业标准80万次提高81.46%，终止试验。
第2根前轴，额定轴荷增加10%，按5.5 t计，单侧板簧座上施加的最大、最小垂向载荷分别为80 850、13 475 N，疲劳寿命达标，进行到102.1万次时未出现失效，终止试验。第3根前轴，按第2根条件加载，疲劳寿命达到100万次时未出现失效，终止试验。
5 结论
收起
（1）给出了空心汽车前轴的设计方法，采用变截面变壁厚的矩形截面轴管和组合的板簧座结构，在实现轻量化的同时改善了抗弯扭强度刚度。针对某轴荷5 t的空心前轴，通过有限元模拟揭示了主销孔处壁厚对拳部强度的影响规律，确定了拳部壁厚系数及封堵孔高度系数、宽度系数的取值范围；选用无缝钢管试制出空心前轴样件，较锻造前轴轻量10.86%，样件各处的力学性能较接近，强度指标高于初始管材。
（2）通过轴荷5 t空心前轴样件的刚度试验，揭示了轴体下表面轴向应力垂向位移的变化，结果表明：垂向刚度系数大于11.78 kN/mm，高于行业标准；纵向刚度系数为16.38 kN/mm，远高于行业标准。
（3）通过轴荷5 t空心前轴样件的垂向工况静强度试验，揭示了轴体下表面轴向应力的变化规律，揭示了拳部外端面封堵孔边缘的应力分布特性，结果表明：轴向拉应力最大部位的强度系数为6.13，高于行业标准；拳部端面封堵孔边缘处的应力数值较小，对强度几乎无影响。
（4）进行了轴荷5 t空心前轴样件的垂向工况疲劳试验，结果表明：最大载荷3倍额定轴荷下的疲劳寿命高于145.17万次，最大载荷3.3倍额定轴荷下的疲劳寿命高于100万次，远高于行业标准。
基金
收起
  • *湖北和德工业科技有限公司合作项目（钢管压制成形汽车前轴技术开发）(X2021233)
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2024年第46卷第12期
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doi: 10.19562/j.chinasae.qcgc.2024.12.019
  • 接收时间：2024-05-20
  • 首发时间：2025-07-21
  • 出版时间：2024-12-25
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  • 收稿日期：2024-05-20
  • 修回日期：2024-06-17
基金
*湖北和德工业科技有限公司合作项目（钢管压制成形汽车前轴技术开发）(X2021233)
作者信息
    1. 燕山大学，河北省特种运载装备重点实验室，秦皇岛 066004
    2. 燕山大学车辆与能源学院，秦皇岛 066004

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王连东，教授，博士研究生导师，博士，E-mail：。
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2种不同金属材料的力学参数
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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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