Transactions of Materials and Heat Treatment

Title：Research on forward design and reverse reconstruction methods for subframe tubular beams

Authors： Li Huan1 Li Chunyu1 Liu Ning2 Yu Fei3 Yu Zhenlong1 Ma Jun2

Unit： 1. FAW Car Co. Ltd. 2. Academy for Electromechanical Changchun Polytechnic 3.FAWER YTEC Automotive Chassis System Co. Ltd.

KeyWords： subframe tubular beam forming forward design reverse reconstruction dimensional accuracy

ClassificationCode：TG306

year,vol(issue):pagenumber：2024,49(4):104-111

Abstract：

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.

Funds：

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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