锻压技术

副车架管梁正向设计和逆向重构方法研究

英文标题：Research on forward design and reverse reconstruction methods for subframe tubular beams

单位：1.一汽奔腾轿车有限公司 2.长春职业技术学院机电学院 3.富奥威泰克汽车底盘系统有限公司

分类号：TG306

出版年,卷(期):页码：2024,49(4):104-111

摘要：

为解决管梁成形尺寸精度问题，针对某副车架应用的成形管梁，提出一种正向设计和逆向重构的设计方法。应用成形管梁正向结构设计技术，完成前横梁初始结构设计；利用成形数值仿真技术评估了前横梁的尺寸精度，其贴模率为88.8%，最大尺寸偏差为3.20 mm；基于前横梁成形仿真结果模型，对前横梁及与其焊接搭接支架进行逆向重构；依据逆向重构数据完成了前横梁及副车架总成的样件试制，经实物检测前横梁最大尺寸偏差从初始结构的3.20 mm已降低至了逆向重构后的1.02 mm；应用成形管梁的副车架总成最终通过了台架试验150%耐久性考核。综上所述，通过正向设计和逆向重构的设计方法可有效提升管梁成形的尺寸精度，为主机厂开发成形管梁提供了一定的技术参考。

To solve the problem of dimensional accuracy in tubular beams forming, for the formed tubular beams applied to a certain subframe, a design method of forward design and reverse reconstruction was proposed.The initial structural design of front crossbeam was completed by applying the forward structural design technology of formed tubular beams. Then, the dimensional accuracy of front crossbeam was evaluated by forming numerical simulation technology with a die-fitting rate of 88.8% and a maximum dimensional deviation of 3.20 mm. Furthermore, based on the simulation result model of front crossbeam, the reverse reconstruction of front crossbeam and its welded overlap bracket was performed, and based on the reverse reconstruction data, the prototype production of front crossbeam and subframe assembly was completed. After physical inspection, the maximum dimensional deviation of front crossbeam reduced from the initial structure of 3.20 mm to 1.02 mm after reverse reconstruction, and the subframe assembly using formed tubular beams ultimately passed the 150% durability assessment of bench test. The result shows that the design method of forward design and reverse reconstruction can effectively improve the dimensional accuracy of tubular beam forming, providing a certain technical reference for the development of formed tubular beams.

基金项目：

2023年度吉林省高校优秀青年科研创新人才储备库项目；2024年度吉林省科技厅“科创专员（科创副总）”项目；2024年度吉林省教育厅科学研究项目（JJKH20241782KJ）；2022年度吉林省成人教育协会“十四五”成人继续教育科研规划课题（2022CJY140）

作者简介：李欢（1985-）,男，硕士，高级工程师 E-mail：316660026@qq.com 通信作者：刘宁(1986-)，男，硕士，讲师 E-mail：4103677@qq.com

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