Aluminum alloy integrated die-casting technology is an important means to achieve automotive lightweight. In this paper，structure optimization，molding simulation technology，die-casting technology are adopted for "material-structure-process" integrated design and manufacture of shock tower. Firstly，combined with extensive design experience，the three-dimensional data of the shock tower is determined through performance objectives，material selection and structural design. Subsequently，the performance analysis of the shock tower is conducted to ensure that the performance objectives are met，and the mold flow analysis of the temperature and velocity fields is conducted based on the designed mold structure，and optimization measures are proposed. Finally，the parts trial production is carried out to conclude problems and analyze causes，and propose solutions to form the shock tower development process. The study shows that the weight reduction rate of the shock tower reaches 16.5% while meeting the requirements of various performance indexes. The integrated design method is feasible，provides the industry with the ability to analyze the whole process and actual production experience，and enhances the confidence of manufacturers in adopting integrated die-casting technology.

When driving on highways，it's necessary to reduce wind noise in the side window areas of a vehicle. Low-frequency noise control of automobile wind noise can be achieved through Active Noise Control （ANC）. Therefore，an Active Wind Noise Cancellation （AWNC） method for automobile wind noise is proposed in this paper. The suitable input signal of the side window area is selected as the reference signal，which shows good coherence with the target noise in the 100-500 Hz frequency range. Taking a full-scale clay model of the vehicle in a wind tunnel as the research object，the reference signals for wind noise are optimized through the Long Short-Term Memory （LSTM） method. The optimized reference signals are then processed using the FxLMS algorithm for AWNC simulation and validated through hardware dSPACE testing. The results show that the optimized reference signals not only reduce the number of sensors needed，thus saving cost，but also decrease the peak frequency band of wind noise by 5-15 dB.

With the in-depth implementation of China 's ‘carbon peaking and carbon neutrality’ strategy，electric vehicles have developed rapidly. The bonding process of producing drive motor core has attracted more and more attention. In this study，for the problem that the production efficiency is limited due to the uncoordinated rhythm matching of each process in the production process of adhesive iron core，the purpose of reducing production cost and improving production efficiency is achieved by solving the problems of driving device selection and parameter setting of rotary lamination mechanism of adhesive motor core processing equipment. Based on the grey theory，a comprehensive multi-objective optimization method is put forward in this paper，which aims to improve the accuracy of driving device selection and parameter setting of motor core processing equipment.

To study the impact of undulating road on driving stability of hazardous chemical liquid tank truck，the medium and long wave road models are constructed based on road roughness data. Taking a multi-axles liquid tank truck as the object，a vehicle dynamics model considering the tire deformation and suspension nonlinear characteristics is established. Equivalent mechanical models of the longitudinal and lateral sloshing of the liquid are established，which are coupled with the vehicle dynamics model. Kinetic parameters of the tank on different roads are obtained to excite the forced liquid sloshing model. The results show that the increase in the phase difference between the two sides of the road has an adverse effect on the lateral stability of the truck. The frequency of liquid lateral sloshing decreases with the increase of road wavelength and increases with the rise of liquid filling ratio. When the distance between the tractor saddle and the axle of the semi-trailer is an integer multiple of the road wavelength，there is significant longitudinal liquid sloshing. The oblique wave deflector can suppress lateral liquid sloshing，but the suppression effect is poor when the liquid filling ratio is low under small sloshing conditions. When the truck passes through uneven roads with a low filling ratio，increasing the vehicle speed appropriately can reduce the liquid sloshing. While the filling ratio is high，excessive vehicle speed will lead to a significant increase in liquid sloshing amplitude and wall load，reducing the driving stability of the vehicle.

To improve the lightweight level of electric cargo vehicles，a Cell To Frame （CTF） structure that integrates the frame and battery compartment is proposed in this paper. Firstly，a finite element model of the benchmark vehicle frame is established，and its static performance and free mode are calculated. The accuracy of the finite element model is verified through free mode experiments. Then，the fatigue life analysis of the frame is carried out using the nominal stress method in the time domain using the multi working condition combination fatigue load spectrum obtained from road sampling. Next，experimental design is conducted on the initial design of the CTF structure，which has been validated by finite element analysis，and a surrogate model is established. Finally，the global response search method is used for optimization design to obtain the optimal lightweight solution. The results show that after optimized design，the weight of the CTF structure is reduced by 139.95 kg compared to the traditional separation design of the frame and battery compartment，with a lightweight rate of 14.09%. At the same time，the mechanical properties and fatigue life of the CTF structure both meet the design requirements.

In　recent years，mega-casting aluminum alloy structures have gradually been used to replace traditional stamping-welded body-in-white structures. The study on lightweight design of mega-casting aluminum alloy rear floor structure is conduced in this paper. An equivalent analysis scheme is proposed for the analysis of mega-casting vehicle body components. Regarding the processing and performance of the mega-casting structure，the processing constraints for the design are investigated，and the heterogeneity of its material properties is clarified. Based on the topology optimization method，the design domain of the structure is analyzed and the ideal topological design is obtained. Finally，a lightweight design is carried out，achieving a 7% weight reduction while ensuring performance. The study illustrates the design and optimization process of the mega-casting vehicle body components，which has certain reference significance.

Megacasting during rapid filling and cooling processes inevitably generates defects，which significantly impact the mechanical properties of castings. However，it is difficult for existing mechanical analysis models to accurately predict the properties in defective castings，posing substantial challenges to the design of structurally safe castings. To solve the problem，a constitutive model and a fracture criterion of cast aluminum considering defects are proposed in this paper. Five different shapes of samples are cut from different locations of the megacasting floor，and experimental tests are carried out. The defect information on the fracture sections is statistically analyzed using scanning electron microscopy. Based on the stress-strain curves of the standard tensile samples，a constitutive model considering defects and saturating stresses is proposed to accurately characterize the strain-hardening properties. Based on the existing Modified Mohr-Coulomb （MMC） fracture criterion，an improved MMC model considering defects and stress states is proposed，and the parameters are calibrated by four different shaped samples. To validate the effectiveness of the proposed model，a comparative analysis between experimentation and simulation is conducted. The results show that the proposed constitutive model has a high fitting accuracy compared with the traditional hardening model. The load-displacement curves of the tests and simulation of different samples are in good agreement，which verifies the validity of the proposed fracture model. This study provides a novel approach to accurately predicting the mechanical properties of megacasting aluminum alloys.

For the complex thin-walled structure design of the integrated front engine compartment of electric vehicles，a structure and performance collaborative design method based on topology optimization is proposed in this paper. The optimal load path under multiple load conditions is determined through topology optimization and feasibility design of the front engine compartment integrated die-casting component process is conducted. Material testing is conducted on the die-cast materials，and failure surfaces are developed based on stress triaxiality and Lode angle coefficient stress states. A simplified frontal collision model is constructed to assess the stiffness compatibility between the extruded longitudinal beams and the die-cast components within the integrated front compartment structure. The results show that the proposed design method can effectively obtain topological paths under multiple performance constraints，fully consider the feasibility of the front cabin structure process and structural performance matching，and reduce research and development cost.

The goal of the structural design of a stamping die is to obtain the optimal structural configuration and the corresponding size parameters while considering both structural performance and die weight，which is difficult to achieve with a single topology optimization process. Therefore，a design method combining topology and size optimization for stamping die structure is proposed in this paper. The method avoids the complicated load mapping calculation step by adopting the node-to-node load mapping strategy，thus directly transferring the load distribution on the contact surface to the loading step in the static model. The relaxation coefficients of the structural performance in the topology optimization model are determined by the given performance evaluation index and the corresponding selection strategy so that the mechanical properties of the topology optimized dies are not weaker than those of the initial design while reducing the weight as much as possible. Finally，according to the optimal structural configuration obtained from the topology optimization，the corresponding structural parameters are determined by the multiple surrogate models-based size optimization method. The method is successfully applied to the optimal design of stamping dies for automotive structural components and its effectiveness is verified by comparing the results of the initial design，topology-optimized design，and topology size joint optimization design.

In order to develop a hood with better pedestrian protection performance，firstly three types of straw energy absorption modules are designed，specifically circular，triangular and rectangular. Subsequently，the CSEAM sample with PA11 material is prepared and the finite element model is verified. Then，the human body injury protection effectiveness of the three types of Novel Straw-shaped structure Sandwich Hood （NSSH） is evaluated by simulation and the deformation mode is analyzed. The results show that the three NSSHs can significantly reduce pedestrian head injury，and the Triangle Straw-shape structure Sandwich Hood （TSSH） has the best protective effectiveness on human body injury. The deformation is uniformly diffused in a regular shape，and the peak of acceleration and impact force in each stage of the collision waveform is optimized by reducing the overall structural stiffness of the hood. Further analysis shows that the human body injury protection effectiveness of TSSH decreases with the increase of vehicle speed and impact angle，and the injury caused by TSSH is significantly lower than that of the original hood，indicating that raising the hood can reduce the impact angle to better protect pedestrians，while when the Ratio of Pedestrian height to Bonnet leading edge height R_h≤2.1 and R_h≥2.45，the head only impacts the hood and windshield，respectively. It can be used as the criterion of hood lift. The research results can provide support for the design of hood structure with better pedestrian protection effectiveness.