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Lightweight Design and Optimization of Integrated Die Casting Aluminum Alloy Front Cabin
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Zhiling Fang1, 2, Yanli Song2, Jie Kang1, Xinghong Zhang1, Dan Zhang1
Automotive Engineering | 2024, 46(7) : 1314 - 1322
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Automotive Engineering | 2024, 46(7): 1314-1322
Lightweight Design and Optimization of Integrated Die Casting Aluminum Alloy Front Cabin
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Zhiling Fang1, 2, Yanli Song2, Jie Kang1, Xinghong Zhang1, Dan Zhang1
Affiliations
  • 1. Dongfeng Motor Corporation Research & Development Institute,Wuhan  430056
  • 2. Wuhan University of Technology,Hubei Key Laboratory of Advanced Technology for Automotive Components,Wuhan  430070
Published: 2024-07-25 doi: 10.19562/j.chinasae.qcgc.2024.07.018
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The requirement of low carbon and lightweight in the auto industry is growing now. The new mega-casting technology applied on vehicle body can better achieve weight, cost and emission reduction, and has become spotlight to automobile manufacturers. In this paper, the traditional steel front compartment of passenger car body is replaced by integrated die casting part, and lightweight design on the aluminum alloy integrated front engine compartment is conducted. The optimal load path for stiffness is obtained through topology optimization of the front cabin by SIMP method. Considering the castability of the front cabin, the draft direction, thickness size and position distribution of the ribs are designed. Frontal impact simulation is conducted according to C-NCAP2021 and the impact resistance of the integrated die cast body is improved through Taguchi experimental design method and response surface optimization. Simulation analysis is conducted on the optimized performance of the white body. Compared with the traditional scheme, the weight of the optimal design is reduced by 13.9%, with the bending stiffness of the BIW increased by 9.7%, and the first modal meets the requirements. The research in this paper is meaningful for the platform design and industrialized application of integrated die casting car body structure in the future.

integrated die casting  /  lightweight design  /  crashworthiness  /  front cabin
Zhiling Fang, Yanli Song, Jie Kang, Xinghong Zhang, Dan Zhang. Lightweight Design and Optimization of Integrated Die Casting Aluminum Alloy Front Cabin[J]. Automotive Engineering, 2024 , 46 (7) : 1314 -1322 . DOI: 10.19562/j.chinasae.qcgc.2024.07.018
Year 2024 volume 46 Issue 7
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Article Info
doi: 10.19562/j.chinasae.qcgc.2024.07.018
  • Receive Date:2023-12-05
  • Online Date:2025-07-29
  • Published:2024-07-25
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History
  • Received:2023-12-05
  • Revised:2024-01-28
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Affiliations
    1. Dongfeng Motor Corporation Research & Development Institute,Wuhan  430056
    2. Wuhan University of Technology,Hubei Key Laboratory of Advanced Technology for Automotive Components,Wuhan  430070
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表12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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