车身结构抗撞性问题的简化建模及优化方法研究
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摘要
车身设计作为汽车核心技术之一,已经成为我国自主品牌提高产品核心竞争力不可或缺的技术。汽车行业“十一五”规划有针对性地提出：“大型汽车集团必须具备自主产品的平台、总成研发能力；骨干企业则必须具备车身和动力总成、底盘的匹配能力；零部件企业则必须掌握主要的动力总成和关键零部件的核心技术,并具备平台的同步研发能力,鼓励自主品牌轿车发展”。2011年是我国“十二五”规划的起始年,是能否妥善应对国内外发展环境重大变化的关键时期,汽车产品在节能、减排、安全等方面应进一步与世界接轨。坚持把科技进步和创新作为加快转变经济发展方式的重要支撑是制定“十二五”规划的基本原则之一,更是汽车产业由“中国制造”升级到“中国创造”过程中的决定因素。提高原始创新能力和关键核心技术创新能力是实现产品技术升级的保证,特别是当前激烈的市场竞争和成本制约下,将车身设计的更多性能分析和优化工作集中于前期的概念设计阶段,可极大地降低后续工作中修改原设计带来的风险及成本。作为衡量汽车被动安全性的关键因素,车身结构的抗撞性能也需要在概念设计阶段被有效地评估。这就凸显了车身碰撞简化建模方法和理论研究的重要性。
本文结合2009年度国家自然科学基金面上项目《基于重分析理论的简化车身多单元框架结构截面参数快速优化研究》(编号：50975121),2009年度吉林省科技发展计划重大项目《简化车身框架结构多目标多层次快速优化关键技术研究》(编号：20096004)以及配套的中国第一汽车集团公司联合行动项目《乘用车碰撞参数化模型技术研究》(集团编号：0846),中国第一汽车集团公司科技创新项目《车身性能多目标优化平台建立》(集团编号：0837和093715)关于简化车身框架结构静力学分析及优化问题的研究成果,对适用于碰撞分析的简化车身结构建模理论及结构抗撞性优化设计方法进行了深入的研究。主要工作包括：
第一,分析了箱型截面薄壁梁结构在弯曲载荷作用下的变形机理,并提出了一种改进的基于能量守恒的弯曲特性分析方法—CKW方法,保证了理想塑性弯曲区域的面内变形模式满足运动学容许条件。当薄壁直梁结构无法再承受额外的载荷时,弯曲抗性急剧下降,随之在局部表面出现褶皱变形,此时的塑性变形集中在很狭窄的塑性铰区域,其余部位可视为无变形的刚体。基于运动学方法假定了一系列由于局部非线性屈曲变形而产生的塑性铰线,来近似地描述溃缩过程中的能量耗散途径,进而获得了总体能量率的表达式,并通过计算得到了结构的抗弯特性曲线。基于CKW方法的箱型截面薄壁梁弯曲特性分析理论为后续研究其它截面形式下的薄壁梁结构弯曲特性提供了理论基础。
第二,基于所提出的箱型截面弯曲特性分析的CKW方法,对不同类型的帽型截面薄壁梁的弯曲机理进行了研究,并对各自的局部塑性铰区域的褶皱变形特征进行了分析。提出了在单帽型截面梁结构沿截面短边发生屈曲,以及槽型截面在Flange面内发生屈曲(两种弯曲形式)这三种变形模式的结构弯曲特性简化计算方法。这部分研究内容是详细对标车身结构进行框架模型缩减工作的理论基础,为实际车身模型中复杂截面梁结构的等效和简化处理提供了更多的解决方案；
第三,基于所提出的多种截面形式的薄壁梁弯曲特性计算方法,研究了建立适用于碰撞分析的简化车身模型的方法和流程。选择车身最主要吸能部件的典型碰撞工况,前纵梁的前部碰撞和B柱结构的顶部压溃工况为例,分别提取了各自的抗弯特性曲线。基于LS-DYNA讨论了建立简化模型的方法和流程,通过合理分布塑性铰,利用非线性梁单元和附带抗弯特性的转动弹簧单元来近似模拟实际的碰撞模型。详细模型和简化模型的碰撞变形历程、吸能曲线、刚性墙位移等碰撞性能参数的对比结果,均显示了简化建模过程中采用的薄壁梁弯曲特性推导方法和建模流程的正确性和合理性。
第四,对标车身主要吸能部件的碰撞分析结果显示了在抗撞性方面存在着性能缺陷。对部件的详细模型进行抗撞性优化设计,可提高车身产品的性能和竞争力,也能够为车身缩减工作提供更可靠的样本。以对标车身的前纵梁结构为研究对象,应用了应变能密度法来提取结构承载贡献量分布形式。根据计算得到的应变能密度分布将前纵梁结构划分为不同区域,基于变密度法进行了拓扑优化,获得不同区域内的材料分布最优形式。为改善前部碰撞工况下的变形模式并提高吸能性,对比了工程实际中常见的吸能结构设计方法,综合考虑了结构造型和可加工性等因素,在前端直梁区域边缘部位均匀布置了小尺寸方形诱导槽,并在需要加强的区域内部贴装了加强板。最终的碰撞分析显示了所采用的模型修改理论和措施使前纵梁结构具备了极佳的溃缩变形模式和能量吸收能力。
第五,研究了另一种解决车身结构非线性碰撞优化问题的方法——基于代理模型的优化技术,并为碰撞缓冲器结构的低速抗撞性优化设计问题提出了解决方案。结合了正交组合试验设计在构造响应代理模型上的优势,在设计空间中合理分布试验点,分别建立了统计性好,拟合精度高的吸能量和最大碰撞力的响应面模型。而后应用自适应响应面优化方法从提高抗撞性并兼顾轻量化设计的角度对碰撞缓冲器结构的4个构成部件进行了厚度优化,整个优化过程进行了16步迭代就达到了收敛,并获得了最优解。在总质量及最大碰撞力略有下降的情况下,结构可吸收的能量值提升了近5%,达到了预期的优化目标。
最后,对全文进行了系统的总结并对未来的工作进行了展望。
Autobody design is one of the core technologies in automobile industry. It is absolutely necessary for independent enterprises to improve the competitiveness of core products. Automotive industry, "Eleventh Five-Year Plan", targetedly put forward that:"Large Automotive Group must have a platform for independent product, assembly of R& D capabilities; Key enterprises must have the ability to match among autobody, powertrain and chassis; Parts enterprises must master the major powertrain components and core technologies and R& D capabilities with the platform synchronization and the development of own-brand cars was encouraged".2011 is the initial year of "Twelfth Five-Year Plan", and it is the key stage of coping with the significant changes at home and abroad. The independent automobile products must make further efforts on the energy conservation, emission reduction and safty demands to reach the advanced level. The development of technology progress and innovation as one of the fundamental principles, is the important support of accelerated transformation of the economic development mode. Moreover, it is the determinant factor of changing the automobile products from " Made in China" to "Create in China". Improve the initial and core technology innovation capability are the assurances of the production technology upgrade. Particularly, under the intense trade competition and cost containment, the risks and costs in the follow-up modification works can be enormously reduced by making the main efforts on the performance analysis and optimization during conceptual design stage. As the critical measurement factor of automobile passive safety, autobody crashworthiness must be effectively evaluated during the conceptual design stage. That explicity reveals the importance of autobody simplified modeling method and theory research.
This thesis is based on the research of simplified body framework modeling, static analysis and optimization supported by National Natural Science Foundation of China (No. 50975121), Science and Technology Development Plan of Jilin province (No.20096004) and its assorted project, FAW Group Combined Action Plan (No.0846), and FAW Group Science and Technology Innovation Project (No.0837 and 093715). The thesis intensively investigates the modeling method and theory of simplified crash autobody structure, as well as the crashworthiness design and optimization method of the detailed structures. The main work includes:
First, the bending collapse mechanism of the thin-walled beam with box section is analyzed. Then, the simplified numerical computational method, called CKW method of bending characteristics is put forward based on the energy conservation. This modified numerical computational method meets kinematically admissible. Bending resistance capability of the thin-walled beam decrease rapidly when the straight structure could not stand the additional loading. By that time, the wrinkle appears on the local surface and the plastic deformation is concentrated on a narrow plastic hinge area. And other non-deformation parts of the beam can be treated as rigid body. The energy dissipation paths during the bending collapse are approximately represented by the assumptive plastic hinge lines which constitute the buckling deformation area. Finally, the total rate of energy dissipation along the plastic hinges are obtained, and the curve of bending resistant is analyzed. The CKW method provides a basis for the bending characteristics derivation of thin-walled beams with other sectional shapes.
Second, based on the proposed CKW bending theory of box section, the bending mechanism of different thin-walled beams with hat-like section are deeply investigated. And the wrinkle characteristics of the local plastic hinge areas are analyzed, respectively. The simplified computational method for predicting bending characteristics of three plastic bending modes, including bending along the short side of thin-walled beam with top-hat section, in-plane tensile and in-plane collapse modes on flange surface of channel section beam are put forward. This work is the foundation of modeling the simplified body frame which reduced from the initial comparative autobody structure.
Third, the simplified modeling method and process of autobody structure with crashworthiness analysis capability are discussed. Those methods are based on the bending computational theory of thin-walled beam proposed previously. The main crash energy absorption components, the frontal rail and B pillar, as well as their different crash conditions with frontal crash and roof crush are choosen as research objects, then their bending resistant characteristics are abstracted. By using LS-DYNA, the simplified method and process are applied based on the computational characteristics. In the simplified model, by distributing the plastic hinge area, nonlinear beam elements and rotational springs with bending characteristics are used to simplify the existing detailed models by replacing the shell elements. The comparisons of the crashworthiness parameters, such as the crush deformation curve, energy absorption, and rigid-wall displacement between the detailed and simplified models show the validity and reasonability of the proposed bending computational theory of thin-walled beams and the simplified modeling method of autobody structure.
Fourth, in order to modified the crashworthiness defects of the comparative autobody structure, so as to improve the performance and competitive power of body products, the main energy absorption component is taken to analyze and optimize the crashworthiness capability. Moreover, the better detailed model can supply better sample to the simplified modeling. Strain-energy-density method is proposed here to analyze the load bearing distribution among the frontal rail. Based on the calculated strain-energy-density results, the initial structure is divided into several domains. By using topology optimization technology based on variable density method, the optimal material distribution among different domains are obtained. For the purpose of improving deformation mode and energy absorption capability, the small size tiggers with square shape are distributed uniformly on the corners of the frontal straight part, and the reinforcement plates are picked and placed inside the weaker domains. Those modified strategies are taken the usual energy absorption structural design method, as well as configuration design and processablity into account. The final crash analysis indicates that the modified rail model has an extremely excellent collapse mode and energy absorption capability.
Fifth, another effective method on solving nonlinear crashworthiness optimization problem as known as surrogate model technology is investigated here. By the surrogate method, the optimal design is proposed to improve the low-speed crashworthiness performance of crash box structure. By taking the advantages of the response surrogate modeling based on orthogonal-composite experimental design, the reasonable design samples are distributed in the design space. Then, the response surface models of total energy absorption and peak crash force with excellent statistical characteristics and precise fitting capability are obtained, respectively. The adaptive response surface optimization method is employed here to solve the crashworthiness optimization problem by considering the lightweight demand. The thickness of four key components are taken into account, and the optimal result convergences at the sixteen step in the optimization process. The final comparisons show that total energy absorption is raised nearly 5%, meanwhile, the mass and peak crash force are slightly decreased. The optimal method and results have successfully achieved the expected targets.
Finally, the main content is summarized and prospects for the futher work is predicted.
本文结合2009年度国家自然科学基金面上项目《基于重分析理论的简化车身多单元框架结构截面参数快速优化研究》(编号：50975121),2009年度吉林省科技发展计划重大项目《简化车身框架结构多目标多层次快速优化关键技术研究》(编号：20096004)以及配套的中国第一汽车集团公司联合行动项目《乘用车碰撞参数化模型技术研究》(集团编号：0846),中国第一汽车集团公司科技创新项目《车身性能多目标优化平台建立》(集团编号：0837和093715)关于简化车身框架结构静力学分析及优化问题的研究成果,对适用于碰撞分析的简化车身结构建模理论及结构抗撞性优化设计方法进行了深入的研究。主要工作包括：
第一,分析了箱型截面薄壁梁结构在弯曲载荷作用下的变形机理,并提出了一种改进的基于能量守恒的弯曲特性分析方法—CKW方法,保证了理想塑性弯曲区域的面内变形模式满足运动学容许条件。当薄壁直梁结构无法再承受额外的载荷时,弯曲抗性急剧下降,随之在局部表面出现褶皱变形,此时的塑性变形集中在很狭窄的塑性铰区域,其余部位可视为无变形的刚体。基于运动学方法假定了一系列由于局部非线性屈曲变形而产生的塑性铰线,来近似地描述溃缩过程中的能量耗散途径,进而获得了总体能量率的表达式,并通过计算得到了结构的抗弯特性曲线。基于CKW方法的箱型截面薄壁梁弯曲特性分析理论为后续研究其它截面形式下的薄壁梁结构弯曲特性提供了理论基础。
第二,基于所提出的箱型截面弯曲特性分析的CKW方法,对不同类型的帽型截面薄壁梁的弯曲机理进行了研究,并对各自的局部塑性铰区域的褶皱变形特征进行了分析。提出了在单帽型截面梁结构沿截面短边发生屈曲,以及槽型截面在Flange面内发生屈曲(两种弯曲形式)这三种变形模式的结构弯曲特性简化计算方法。这部分研究内容是详细对标车身结构进行框架模型缩减工作的理论基础,为实际车身模型中复杂截面梁结构的等效和简化处理提供了更多的解决方案；
第三,基于所提出的多种截面形式的薄壁梁弯曲特性计算方法,研究了建立适用于碰撞分析的简化车身模型的方法和流程。选择车身最主要吸能部件的典型碰撞工况,前纵梁的前部碰撞和B柱结构的顶部压溃工况为例,分别提取了各自的抗弯特性曲线。基于LS-DYNA讨论了建立简化模型的方法和流程,通过合理分布塑性铰,利用非线性梁单元和附带抗弯特性的转动弹簧单元来近似模拟实际的碰撞模型。详细模型和简化模型的碰撞变形历程、吸能曲线、刚性墙位移等碰撞性能参数的对比结果,均显示了简化建模过程中采用的薄壁梁弯曲特性推导方法和建模流程的正确性和合理性。
第四,对标车身主要吸能部件的碰撞分析结果显示了在抗撞性方面存在着性能缺陷。对部件的详细模型进行抗撞性优化设计,可提高车身产品的性能和竞争力,也能够为车身缩减工作提供更可靠的样本。以对标车身的前纵梁结构为研究对象,应用了应变能密度法来提取结构承载贡献量分布形式。根据计算得到的应变能密度分布将前纵梁结构划分为不同区域,基于变密度法进行了拓扑优化,获得不同区域内的材料分布最优形式。为改善前部碰撞工况下的变形模式并提高吸能性,对比了工程实际中常见的吸能结构设计方法,综合考虑了结构造型和可加工性等因素,在前端直梁区域边缘部位均匀布置了小尺寸方形诱导槽,并在需要加强的区域内部贴装了加强板。最终的碰撞分析显示了所采用的模型修改理论和措施使前纵梁结构具备了极佳的溃缩变形模式和能量吸收能力。
第五,研究了另一种解决车身结构非线性碰撞优化问题的方法——基于代理模型的优化技术,并为碰撞缓冲器结构的低速抗撞性优化设计问题提出了解决方案。结合了正交组合试验设计在构造响应代理模型上的优势,在设计空间中合理分布试验点,分别建立了统计性好,拟合精度高的吸能量和最大碰撞力的响应面模型。而后应用自适应响应面优化方法从提高抗撞性并兼顾轻量化设计的角度对碰撞缓冲器结构的4个构成部件进行了厚度优化,整个优化过程进行了16步迭代就达到了收敛,并获得了最优解。在总质量及最大碰撞力略有下降的情况下,结构可吸收的能量值提升了近5%,达到了预期的优化目标。
最后,对全文进行了系统的总结并对未来的工作进行了展望。
Autobody design is one of the core technologies in automobile industry. It is absolutely necessary for independent enterprises to improve the competitiveness of core products. Automotive industry, "Eleventh Five-Year Plan", targetedly put forward that:"Large Automotive Group must have a platform for independent product, assembly of R& D capabilities; Key enterprises must have the ability to match among autobody, powertrain and chassis; Parts enterprises must master the major powertrain components and core technologies and R& D capabilities with the platform synchronization and the development of own-brand cars was encouraged".2011 is the initial year of "Twelfth Five-Year Plan", and it is the key stage of coping with the significant changes at home and abroad. The independent automobile products must make further efforts on the energy conservation, emission reduction and safty demands to reach the advanced level. The development of technology progress and innovation as one of the fundamental principles, is the important support of accelerated transformation of the economic development mode. Moreover, it is the determinant factor of changing the automobile products from " Made in China" to "Create in China". Improve the initial and core technology innovation capability are the assurances of the production technology upgrade. Particularly, under the intense trade competition and cost containment, the risks and costs in the follow-up modification works can be enormously reduced by making the main efforts on the performance analysis and optimization during conceptual design stage. As the critical measurement factor of automobile passive safety, autobody crashworthiness must be effectively evaluated during the conceptual design stage. That explicity reveals the importance of autobody simplified modeling method and theory research.
This thesis is based on the research of simplified body framework modeling, static analysis and optimization supported by National Natural Science Foundation of China (No. 50975121), Science and Technology Development Plan of Jilin province (No.20096004) and its assorted project, FAW Group Combined Action Plan (No.0846), and FAW Group Science and Technology Innovation Project (No.0837 and 093715). The thesis intensively investigates the modeling method and theory of simplified crash autobody structure, as well as the crashworthiness design and optimization method of the detailed structures. The main work includes:
First, the bending collapse mechanism of the thin-walled beam with box section is analyzed. Then, the simplified numerical computational method, called CKW method of bending characteristics is put forward based on the energy conservation. This modified numerical computational method meets kinematically admissible. Bending resistance capability of the thin-walled beam decrease rapidly when the straight structure could not stand the additional loading. By that time, the wrinkle appears on the local surface and the plastic deformation is concentrated on a narrow plastic hinge area. And other non-deformation parts of the beam can be treated as rigid body. The energy dissipation paths during the bending collapse are approximately represented by the assumptive plastic hinge lines which constitute the buckling deformation area. Finally, the total rate of energy dissipation along the plastic hinges are obtained, and the curve of bending resistant is analyzed. The CKW method provides a basis for the bending characteristics derivation of thin-walled beams with other sectional shapes.
Second, based on the proposed CKW bending theory of box section, the bending mechanism of different thin-walled beams with hat-like section are deeply investigated. And the wrinkle characteristics of the local plastic hinge areas are analyzed, respectively. The simplified computational method for predicting bending characteristics of three plastic bending modes, including bending along the short side of thin-walled beam with top-hat section, in-plane tensile and in-plane collapse modes on flange surface of channel section beam are put forward. This work is the foundation of modeling the simplified body frame which reduced from the initial comparative autobody structure.
Third, the simplified modeling method and process of autobody structure with crashworthiness analysis capability are discussed. Those methods are based on the bending computational theory of thin-walled beam proposed previously. The main crash energy absorption components, the frontal rail and B pillar, as well as their different crash conditions with frontal crash and roof crush are choosen as research objects, then their bending resistant characteristics are abstracted. By using LS-DYNA, the simplified method and process are applied based on the computational characteristics. In the simplified model, by distributing the plastic hinge area, nonlinear beam elements and rotational springs with bending characteristics are used to simplify the existing detailed models by replacing the shell elements. The comparisons of the crashworthiness parameters, such as the crush deformation curve, energy absorption, and rigid-wall displacement between the detailed and simplified models show the validity and reasonability of the proposed bending computational theory of thin-walled beams and the simplified modeling method of autobody structure.
Fourth, in order to modified the crashworthiness defects of the comparative autobody structure, so as to improve the performance and competitive power of body products, the main energy absorption component is taken to analyze and optimize the crashworthiness capability. Moreover, the better detailed model can supply better sample to the simplified modeling. Strain-energy-density method is proposed here to analyze the load bearing distribution among the frontal rail. Based on the calculated strain-energy-density results, the initial structure is divided into several domains. By using topology optimization technology based on variable density method, the optimal material distribution among different domains are obtained. For the purpose of improving deformation mode and energy absorption capability, the small size tiggers with square shape are distributed uniformly on the corners of the frontal straight part, and the reinforcement plates are picked and placed inside the weaker domains. Those modified strategies are taken the usual energy absorption structural design method, as well as configuration design and processablity into account. The final crash analysis indicates that the modified rail model has an extremely excellent collapse mode and energy absorption capability.
Fifth, another effective method on solving nonlinear crashworthiness optimization problem as known as surrogate model technology is investigated here. By the surrogate method, the optimal design is proposed to improve the low-speed crashworthiness performance of crash box structure. By taking the advantages of the response surrogate modeling based on orthogonal-composite experimental design, the reasonable design samples are distributed in the design space. Then, the response surface models of total energy absorption and peak crash force with excellent statistical characteristics and precise fitting capability are obtained, respectively. The adaptive response surface optimization method is employed here to solve the crashworthiness optimization problem by considering the lightweight demand. The thickness of four key components are taken into account, and the optimal result convergences at the sixteen step in the optimization process. The final comparisons show that total energy absorption is raised nearly 5%, meanwhile, the mass and peak crash force are slightly decreased. The optimal method and results have successfully achieved the expected targets.
Finally, the main content is summarized and prospects for the futher work is predicted.
引文
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