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在客车研发的概念阶段引入拓扑优化设计,能够得到符合结构承载特性的最优材料分配方案,对车身的结构安全性和轻量化具有重要意义。但是由于客车有限元模型单元数庞大,同时客车的实际运行工况复杂,使得拓扑优化分析耗时耗力,而分析结果的参考价值却比较低。文中引入子结构方法,将不进行优化的部分凝聚为超单元参与拓扑优化分析,极大地节约了分析时间。同时,采用基于载荷等效法的边界条件建模方法,提高了拓扑优化结果的有效性。基于以上方法对某空气悬架客车的顶棚、侧围、底架格栅进行了复合工况的拓扑优化,验证了建模方法的有效性。
The introduction of topological optimization design in the concept stage of bus research and development can obtain the optimal material distribution scheme that conforms to the structural bearing characteristics and is of great significance to the structural safety and light weight of the vehicle body. However, due to the large number of finite element models of passenger cars and the complicated operating conditions of buses, the topology optimization analysis is time-consuming and labor-intensive, while the reference value of the analysis results is relatively low. In this paper, the substructure method is introduced, and the unoptimized parts are aggregated into superelements to participate in the topology optimization analysis, which greatly saves the analysis time. At the same time, the boundary condition modeling method based on load equivalence method is used to improve the effectiveness of topology optimization results. Based on the above method, the topological optimization of composite roof is carried out on the roof, side walls and undercarriage of an air suspension bus, and the validity of the modeling method is verified.