Collapse behavior evaluation of hybrid thin-walled member by stacking condition

The recent trend of vehicle design aims at crash safety and environmentally-friendly aspect. For the crash safety aspect, the energy absorbing members should absorb collision energy sufficiently but for the environmentally-friendly aspect, the vehicle structure must be light weight in order to improve the fuel efficiency and reduce the tail gas emission. Therefore, the light weight of vehicle must be achieved in a securing safety status of crash. An aluminum or carbon fiber reinforced plastics (CFRP) is representative one of the light-weight materials. Based on the respective collapse behavior of aluminum and CFRP member, the collapse behavior of hybrid thin-walled member was evaluated. The hybrid members were manufactured by wrapping CFRP prepreg sheets outside the aluminum hollow members in the autoclave. Because the CFRP is an anisotropic material whose mechanical properties, such as strength and elasticity, change with its stacking condition, the effects of the stacking condition on the collapse behavior evaluation of the hybrid thin-walled member were tested. The collapse mode and energy absorption capability of the hybrid thin-walled member were analyzed with the change of the fiber orientation angle and interface number.     

热成形淬火工艺中加热炉关键技术参数

汽车轻量化是降低燃油消耗及减少排放的有效途径之一。为了给汽车用户提供最高等级的安全性能,同时又要实现汽车减重,现多数商用汽车制造商开始采用高强度轻重量的热成形零部件。然而根据热成形件质量的要求,需要着重考虑加热过程中的几个关键技术参数(温度均匀性,气氛保护,露点控制),并结合不同加热炉的结构特点,比较了相互的优缺点。结果表明,辊底式加热炉性能要优于多层箱式炉。     

基于薄壁梁落锤压溃高强钢动态力学性能分析

先进高强钢对汽车的安全性和轻量化具有重要影响,其动态力学性能直接影响到整车碰撞安全。针对汽车用先进高强钢的动态力学性能进行分析,选取双相高强钢HC500/DP780,分别采用普通力学拉伸试验机和液压伺服高速拉伸试验机,获得0.001和0.1 s~(-1)的2种准静态下以及1,10,100,200,500和1000 s~(-1)的6种高应变速率下的单向拉伸试验力学性能,并基于Johnson-Cook方程获得材料的动态力学本构模型。基于薄壁梁落锤压溃试验平台进行压溃性能分析,并采用LS-DYNA进行模拟仿真分析,以此对材料动态力学性能数据及本构模型进行验证分析。结果可知:模型仿真与试验分析的变化趋势基本一致,表明模型仿真的准确性,进而说明材料动态力学性能及本构模型的准确性;随着碰撞速率的增加,管件的吸能比以及载荷比都在减小,这说明碰撞速率对管件的吸能特性有一定影响,随着碰撞速率增加,管件的吸能特性逐渐降低。     

汽车工业中的铝合金及其焊接技术

铝及其合金在汽车工业的应用中具有轻量化、节能减排、改善环境、提高汽车平稳性和安全性等特点。铝及其合金熔化焊存在焊缝易产生气孔,焊接接头易软化等缺陷。讨论了激光-电弧复合焊、激光拼焊、搅拌摩擦焊在汽车用铝及其合金焊接的应用和特点。     

基于吸能目标的汽车前端结构刚度匹配性设计

汽车被动安全开发中,一般通过设置薄壁梁吸能结构的强度梯度来满足不同程度的碰撞工况下吸能要求。而充分且稳定的变形,将有利于提高结构吸能效率以及保证较好的维修经济性。以中大型乘用车前端结构在正面碰撞工况下合理的吸能占比作为设计目标值,借助理论计算和有限元仿真分析确定初步设计方案,并在此基础上进行结构间刚度匹配性优化设计。研究结果表明:基于吸能目标的汽车前端结构刚度匹配性设计方法,在满足吸能要求的同时,其结构间的刚度匹配性较好,在不同程度的碰撞工况下,都能按照理想的模式发生变形,满足设计要求。     

Bridging the Design–Manufacturing–Materials Data Gap: Material Properties for Optimum Design and Manufacturing Performance in Light Vehicle Steel-Intensive Body Structures

As safety and fuel economy regulations become increasingly more challenging around the world, light vehicle manufacturers are facing increasing pressure to reduce the weight of their vehicles cost effectively while maintaining or improving safety performance. Optimum light vehicle steel body structure weight and performance are achieved when the constraints of design, manufacturing, and material properties are considered simultaneously. ArcelorMittal has invested heavily over the past several years to close the gap between material property knowledge and the inter-relation between material performance and design and manufacturing efficiency. Knowledge gained through this process is presented and the importance of achieving this simultaneous 3-way optimization is illustrated by a lightweight steel door design example from ArcelorMittal??s S-in motion catalog of lightweight steel solutions.     

电化学刻蚀法制备铝合金超疏水表面及其润湿性转变

目的通过简易环保的方法在铝合金基体上制备超疏水表面。方法采用电化学刻蚀和空气中保存法在铝合金基体上制备超疏水表面,用扫描电子显微镜、粗糙度测量仪和光学接触角测量仪对所得样品的微观形貌、表面粗糙度和润湿性进行分析。结果水滴在铝合金表面的接触角随着保存时间的增加而增大,电化学刻蚀所得超亲水表面逐渐表现出超疏水特性。12 d后表面趋于稳定,水滴在铝合金表面的接触角和滚动角分别为(152.3±4.5)°和(6.4±2.2)°。随着电化学刻蚀时间的增加,铝合金表面的润湿性减小。热处理可以使超疏水表面转为超亲水表面,在空气中保存后表面又恢复疏水性。结论试验所用中性环保的NaCl溶液作为电解液,极大地降低了试验对人体和环境的危害。并未使用有害的二次化学涂层作为表面能修饰材料,提高了试验的安全性和超疏水表面的稳定性。通过此简单环保的电化学刻蚀和空气中保存的方法成功地在铝合金基体上制备出了超疏水表面,所得表面展现出良好的疏水特性。     

Resistance and friction stir spot welding of DP600: a comparative study

Abstract

Efforts to reduce vehicle weight and improve crash performance have resulted in increased application of advanced high strength steels (AHSS) and a recent focus on the weldability of these alloys. Resistance spot welding (RSW) is the primary sheet metal welding process in the manufacture of automotive assemblies. Friction stir spot welding (FSSW) was invented as a novel method to spot welding sheet metal and has proven to be a potential candidate for spot welding AHSS. A comparative study of RSW and FSSW on spot welding AHSS has been completed. The objective of this work is to compare the microstructure and mechanical properties of Zn coated DP600 AHSS (1·2 mm thick) spot welds conducted using both processes. This was accomplished by examining the metallurgical cross-sections and local hardnesses of various spot weld regions. High speed data acquisition was also used to monitor process parameters and attain energy outputs for each process. Results show a correlation found among microstructure, failure loads, energy requirements and bonded area for both spot welding processes.     

基于C-NCAP正面碰撞的某电动车乘员侧气囊虚拟设计及仿真

最新的C-NCAP测试工况包含了64 km／h的偏置碰及50 km／h的全正碰,对安全气囊的设计要求更高。基于某款从B级车平台开发的电动车,利用虚拟设计及CAE分析设计出满足C-NCAP碰撞5星目标要求的乘员侧气囊。通过气囊概念设计-车内爆炸模拟-静态展开试验-整车碰撞仿真的研究方法,获得整车碰撞优化配置参数,碰撞试验结果与仿真耦合理想。此项虚拟设计采用与物理验证相结合的方法,有助于高效地定义乘员侧气囊的设计参数。     

液压蓄能式车辆制动能量回收系统的AMESim仿真研究

建立车辆液压蓄能式制动能量回收装置的AMESim仿真模型,对其工作过程中的能量损耗情况和制动性能的影响因素进行仿真研究。仿真结果表明:能量回收制动过程中,由于车辆行驶阻力造成的损失占车辆总动能的16%,是能量损失的主要方面;提高能量回收效率的办法是提高蓄能器预充气压力或减小蓄能器体积;改变液压泵/马达排量对提高能量回收效率的影响不大,但可显著影响车辆的起动和制动时间。     

Effect of the cutting process on the fatigue behaviour of press hardened and high strength dual phase steels

Press hardened 22MnB5 steels are steady broadening their applications in vehicles since they allow to meet the increasing demands for weight reduction and safety standards. Press hardened parts have been typically applied as structural reinforcements where high rigidity and crash resistance are required. However, the need for further weight reductions in vehicles leads to potential applications in chassis areas, where parts must face up to cyclic loads. The fatigue behaviour of the press hardened 22MnB5 steel and the effect that post-forming processes (such as trimming or punching that usually follows press hardening) on the fatigue behaviour is scarcely known. Thus, the aim of this work is to analyse the fatigue behaviour of 22MnB5 press hardened steels cut using different strategies. The fatigue limit has been obtained in tensile samples of 22MnB5 with an Al–Si coating. Samples were cut by laser and shearing with two different clearance values. Results are compared to those obtained with a high drawing quality mild steel and a dual phase steel with a tensile strength of 1000 MPa, DP1000. It is shown that the fatigue behaviour of press hardened 22MnB5 steels and DP1000 is governed by the defects introduced in cut edges, while the behaviour of the mild steel is almost independent of the cut edge quality. This finding indicates that high strength steels are markedly sensitive to pre-existent defects, such as burr, cracks at the cut edge or surface cracks, and they can be considered as low damage tolerant steels. On the contrary, mild steels are highly damage tolerant, i.e. the fatigue life is mainly independent of the initial defect size. In press hardened 22MnB5, even when cut edges have a high surface quality, the fatigue limit is still limited by the presence of cracks in the brittle Al–Si coating. Crack propagation due to the low damage tolerance capacity of the press hardened steel has been successfully rationalized through a fracture mechanics approach. Thus, if coated press hardened 22MnB5 steels are to be applied in vehicle components subjected to cyclic loads, they must be designed following fracture mechanics concepts to state the safe loading conditions for adequate fatigue resistance.     

储氢材料的应用与发展

车用镍氢电池性能优良、安全可靠、技术成熟稳定,是混合动力车(HEV)比较理想的辅助动力。随着混合动力车技术的不断发展,动力电池用储氢合金将迎来一个黄金发展期。此外,随着燃料电池技术的日益成熟与发展,以氢气为燃料的电动汽车也将迅速发展起来,这就要求必须有安全高效的贮氢系统与之相匹配。传统的液态及高压气态贮氢方式由于成本、质量、体积大小以及安全性等因素限制,无法应用于车载贮氢系统。相比之下,金属氢化物作为一种新型的能源材料,具有贮氢密度高、安全高效及环境友好等优点,将成为未来车载燃料电池的氢载体。文章主要对近期Ni/MH电池用储氢合金的种类和发展以及高容量镁基储氢材料方面的研究工作做一些综述分析,以期为未来的研究工作提供参考。     

铝合金轨道车辆结构及合金性能(1)

本文分为两篇刊登,本篇介绍了城市轨道交通和高速铁路在节能减排方面的优势及铝合金车体的优越性;综述了铝合金车体制造的关键技术和所用的铝合金材料;对国内外的一些铝合金车辆用型材及车体结构作了简要介绍。     

钛合金在汽车轻量化中的应用

以SmCl3为原料，硼氢化钠为还原剂，低代（2．0G3．0G,4．0G）PAMAM树形分子为模板兼稳定剂、制备出纳米颗粒。实验发现，其他条件相同时，树形分子代数越高，所起的模板作用越显著，即Sm／4．0GPAMAM的复合纳米颗粒粒度均匀，分散度好。应用Virtual Materiale（VM）软件对Sm／PAMAM纳米颗粒进行分子动力学模拟。从分子结构和能量变化角度研究了正则（恒定的NVT）系中复合体系的稳定性及其机理。分子动力学模拟结果显示：4．0GPAMAM更适合于作为模板剂和稳定剂，表明动力学模拟结论与实验结果一致。     

FE Simulation Models for Hot Stamping an Automobile Component with Tailor-Welded High-Strength Steels

Ultra-high-strength in sheet metal parts can be achieved with hot stamping process. To improve the crash performance and save vehicle weight, it is necessary to produce components with tailored properties. The use of tailor-welded high-strength steel is a relatively new hot stamping process for saving weight and obtaining desired local stiffness and crash performance. The simulation of hot stamping boron steel, especially tailor-welded blanks (TWBs) stamping, is more complex and challenging. Information about thermal/mechanical properties of tools and sheet materials, heat transfer, and friction between the deforming material and the tools is required in detail. In this study, the boron-manganese steel B1500HS and high-strength low-alloy steel B340LA are tailor welded and hot stamped. In order to precisely simulate the hot stamping process, modeling and simulation of hot stamping tailor-welded high-strength steels, including phase transformation modeling, thermal modeling, and thermal-mechanical modeling, is investigated. Meanwhile, the welding zone of tailor-welded blanks should be sufficiently accurate to describe thermal, mechanical, and metallurgical parameters. FE simulation model using TWBs with the thickness combination of 1.6 mm boron steel and 1.2 mm low-alloy steel is established. In order to evaluate the mechanical properties of the hot stamped automotive component (mini b-pillar), hardness and microstructure at each region are investigated. The comparisons between simulated results and experimental observations show the reliability of thermo-mechanical and metallurgical modeling strategies of TWBs hot stamping process.     

汽车碰撞试验中跑偏问题浅谈

通过大量的实车碰撞试验,对钢丝绳牵引式汽车碰撞试验中经常出现的几种跑偏情况进行了详细分析,并对法规中关于跑偏问题的规定提出了自己的看法,认为汽车在碰撞时的碰撞角度的偏差以及传感器安装时敏感轴方向的偏差,对最终采集数据的影响很大。     

Hot stamping: manufacturing functional optimized components

Due to rising requirements regarding passenger safety and weight reduction hot stamped components get more and more important regarding security relevant parts because of their high strength. Currently, the new challenge is manufacturing components with locally adjusted mechanical properties in order to simultaneously guarantee structural integrity and energy absorption in case of a crash. Therefore, the so called Tailored Tempering process is a promising strategy controlling the cooling rate of the austenitized blank by local heating of the tool and consequently adjusting microstructure development and resulting mechanical properties. As the adjustment of mechanical properties is a temperature dependent process which is also influenced by process parameters and contact conditions, accurate process knowledge is essential. Within this paper the influence of tool temperature and applied contact pressure on the resulting heat transfer coefficient as well as contact condition between the surfaces of former investigations will be shown in a short overview. Based on the results of these fundamental investigations, design principles for Tailored Tempering process will be derived. Furthermore, a hat-profile geometry will be investigated experimentally and characterized by mechanical tests as well as geometrical aspects like sheet thickness and distortion. Additionally, an FE-Modell based on the results of the thermo-mechanical characterization is build up and validated by comparison with the results of experimental work.     

车体振动模态对疲劳强度的影响分析

铁路运输车辆不断朝着高速以及轻量化方向发展,车体承受着复杂的交变载荷,极大地增加了车体结构疲劳断裂的风险。为探究车体结构振动对车辆结构安全性的影响,利用ANSYS Workbench进行车体模态仿真计算。结合服役环境下动车组车体运行模态测试数据,提取出车体1阶菱形(8~9 Hz)、1阶垂弯(12~13 Hz)、1阶横弯(15~16 Hz)及1阶扭转(17~18 Hz)模态频率,对车体有限元模型进行对比修正。利用雨流计数法对部分实测载荷谱数据谱进行处理,得到载荷谱雨流计数矩阵。在模态分析的基础上进行谐响应分析,得到上述不同模态频段范围内的频率响应函数,结合nCode疲劳仿真软件对车体疲劳强度进行仿真计算,得到不同频段范围内车体的疲劳损伤;采用Miner线性累积疲劳损伤理论对仿真计算结果进行疲劳损伤评估,结果表明:车体1阶菱形模态(8~9 Hz)附近频段对车体造成的损伤最大,其损伤位置在车钩与枕梁交接处附近。     

电动汽车液压再生制动系统模糊控制策略的研究

针对纯电动汽车提出一种基于液压再生制动系统的模糊控制策略,综合考虑制动踏板深度、蓄能器压力、蓄电池SOC值等因素对再生制动力分配的影响,并对再生制动力进行合理的分配,在保证制动安全性的前提下,尽可能多地回收制动能量,提高能量利用效率。仿真结果表明:基于液压再生制动系统的模糊控制策略提高了整车能量存储系统的能量使用效率,降低了汽车因制动而带来的能量损失,提高了电动机工作效率。     

浅谈新能源汽车电池框架总成焊接工艺的优化

当前,我国新能源汽车行业步入高速发展阶段,技术和市场成熟度不断提高,关键零部件配套能力大幅提升。新能源汽车增加了电池包,导致整车重量比燃油车大。车重的增加将导致刹车距离更远,对乘员的保护要求更高。电池框架是连接车身与电池包的关键部件,是汽车除轮胎外,最接近地面的部分,经常处于恶劣工况,焊点和焊缝易出现问题。对此,采取满足电池框架焊接强度及尺寸精度要求的焊接工艺,是本文的研究重点。