白车身参数化建模与多目标轻量化优化设计方法研究
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摘要
随着汽车工业的迅速发展，全球汽车保有量大幅增加。汽车在经济领域以及人类生活中已经发挥着巨大的作用，并以越来越大的影响力改变人类的生活与工作，但随着全球汽车保有量的高速提升，对能源、环境和交通安全带来日益巨大的影响。虽然电动汽车为最好解决方案，但就目前的技术水平来说，任何替代方法都还不如石油燃料经济方便。而对于常规燃料汽车来说，目前的开发研究正向高效能、低能耗和排放发展，这些指标都和汽车质量密切相关，汽车轻量化是当前汽车减少油耗和排放的最有效的方法。
汽车车身大多由冲压形成件构成，结构复杂且组成零部件繁多，是整个汽车重要的组成部分。其制作费用占汽车公司投资成本的60%左右，质量约占整车质量的30-40%。在空载状况下，整车所造成的油耗约70%是消耗在车身质量上，因此，车身轻量化是整车轻量化的重要组成部分，也是目前汽车工业的主要研究课题之一。
本文结合国家“十二五”科技支撑计划“汽车关键轻量化技术研发与整车集成应用”的子课题——车身参数化轻量化设计技术研究及其在目标车型上的集成应用项目，以国产某白车身作为研究对象，利用隐式参数化软件SFE-concept分别建立了发动机舱、地板和侧围等车身各几何结构，随之利用映射关系建立各个几何结构之间的参数化装配关系，组成参数化白车身三维实体模型，并通过SFE-concept导出有限元模型。
在得到初始参数化有限元模型后，对其进行了低阶固有频率（主要是一阶扭转和一阶弯曲固有频率）和车身弯扭静刚度分析，并在白车身参数化有限元模型的基础上组建了整车模型，对整车模型的碰撞安全性进行了仿真分析，通过整车正面100%碰撞仿真结果中各部件吸能量在总能量中所占的比重划分了非安全相关零件和正面碰撞安全相关零件。最终与实车白车身刚度与模态试验以及整车碰撞试验结果进行对比，以此证明了本文所建白车身参数化模型的准确性。
进行了白车身低阶固有频率以及弯曲和扭转刚度的灵敏度分析，并对难以进行灵敏度分析的车身梁结构形状变量以及安全相关性能进行了贡献度分析，以作为灵敏度分析的代替。确定了主要用于减重的对车身性能不敏感但对减重较敏感的板厚和形状设计变量以及主要用于性能弥补的板厚设计变量，为车身结构多目标轻量化优化设计提供基础。
根据实际情况，通过对车身非安全件和安全件轻量化优化设计两个步骤完成整个白车身的轻量化优化设计。
以白车身质量和刚度为目标，低阶固有频率为约束进行了白车身非安全件零件厚度的多目标优化设计，优化采用了NSGA-II方法进行了直接优化设计，最终从得到的非劣解前沿中根据偏好选取出最终解。
在进行了非安全件轻量化优化设计的基础上，以白车身质量和整车正面碰撞的乘员舱加速度峰值为目标，白车身固有频率和刚度以及一些正面碰撞安全性的相关参数为约束进行了关于安全件零件厚度和形状变量的多目标优化设计。此优化为间接优化设计，通过椭圆基函数神经网络方法得到近似模型，利用该近似模型进行多目标轻量化优化设计。
进行了两个阶段的轻量化优化设计后，整个白车身的质量由326.22kg降低到了292.95kg，减重效果十分明显，同时该白车身各项性能没有较大的变化，虽然有些性能有小幅降低，但降幅均在7%之内，轻量化系数由初始模型的4.49变化为4.33，结果表明，本文所进行的轻量化优化取得了很好的效果。
With the rapid development of the automotive industry, the car ownership increasedsignificantly in worldwide. The vehicle had played a huge role in human life and economicsphere. The growing influence changed people's life and work. But with the high-speedincreasing in car ownership of the world, it was influenced the energy, the environment andthe traffic safety enormous. Although electric cars was the best solution, at actual technologylevel, any other method could not be more economic than fossil fuel. As for conventionalfuels for cars. Current vehicle research was developing in high efficiency, low energyconsumption and low emissions, which were all close to vehicle quality. So, the vehiclelightweight was most effective ways to reduce the fuel consumption and emissions atpresent.
The body was an important part of the whole vehicle.Most of the vehicle body weremake up of stamping parts, which had a complex structure and was composed of many parts.is an important part of whole. Its expense occupy almost60%of the investment cost. Thebody mass occupy about30-40%of the whole vehicle. In no-live load condition, about70%of the vehicle’s gas consumption was expended on the vehicle body. Therefore, the bodylightweight was important to the vehicle lightweight, also it was one of the main researchsubjects in vehicle industry.
The research was developed based on the project “research on the body parameterizedlightweight design technology and its integrated application on the target models”which wasa part of the National Twelfth five-year Science and Technology Support Program “R&D ofthe key lightweight technology and integrated application on the car”. As a Chinese car wasthe research object, using implicit parameterization software SFE-concept, respectivelyestablished the car body geometry structures such as engine class, floor and side wall. Assembly relationship among the structures were established by using mapping rmethod.Composing three-dimensional solid BIW parameterization model, then, export. the FEMmodel in SFE-concept.
Getting the initial parameterization FEM model, then, the mode and stiffness analysiswere carried out. Based on the BIW model, the whole car was built and the car crashanalysis was carried out. According to the ratio of each parts’ energy absorption to the wholecar’s energy absorption in100%frontal crash of the car, the safety related parts and thenon-safety related parts were distinguished. All of the analysis results were compared withthe experiment. Through the comparison results, the accuracy of the BIW parameterizationmodel was proved.
The sensitivity analysis of the mode and stiffness were carried out. Because the shapevariables and the safety performance were hard to calculate the sensitivity, the relativityanalysis was used instead of the sensitivity analysis. Finally, the variables which were usedfor reducing the body mass and supplementing the performance were determined. Thosevariables were groundwork for the Multi-objective lightweight optimization design.
According to the actual situation, The BIW multi-objective lightweight optimizationdesign was divided into two parts. One was non-safety parts lightweight optimization design,the other was safety parts lightweight optimization design.
As the mass and stiffness of the BIW were the targets, the lower-order naturalfrequency was the constraint, the non-safety parts lightweight optimization design wascarried out. The NSGA-II method was utilized in the optimization. Finally, according to thepreference, the ultimate solution was selected in the Pareto frontier.
Based on the result of non-safety parts lightweight optimization design, the non-safetyparts lightweight optimization design was carried out, in which the mass and the cabinacceleration peak as the targets and the mode, stiffness and the other safety performences asthe constraints. The optimization was indirect. An approximate model was established byusing the EBFNN method, which was utilized in the multi-objective lightweightoptimization design.
After the two optimization process, the mass of the BIW was reduced from326.22kg to292.95kg. The lightweight effect was very obviously, while the performences of the BIWwere changed less Simultaneously. Although some of the performance were less reduced,those reduction were within7%. The lightweight coefficient was reduced from4.49to4.33.The results indicated that the optimization obtained a very well effect.
汽车车身大多由冲压形成件构成，结构复杂且组成零部件繁多，是整个汽车重要的组成部分。其制作费用占汽车公司投资成本的60%左右，质量约占整车质量的30-40%。在空载状况下，整车所造成的油耗约70%是消耗在车身质量上，因此，车身轻量化是整车轻量化的重要组成部分，也是目前汽车工业的主要研究课题之一。
本文结合国家“十二五”科技支撑计划“汽车关键轻量化技术研发与整车集成应用”的子课题——车身参数化轻量化设计技术研究及其在目标车型上的集成应用项目，以国产某白车身作为研究对象，利用隐式参数化软件SFE-concept分别建立了发动机舱、地板和侧围等车身各几何结构，随之利用映射关系建立各个几何结构之间的参数化装配关系，组成参数化白车身三维实体模型，并通过SFE-concept导出有限元模型。
在得到初始参数化有限元模型后，对其进行了低阶固有频率（主要是一阶扭转和一阶弯曲固有频率）和车身弯扭静刚度分析，并在白车身参数化有限元模型的基础上组建了整车模型，对整车模型的碰撞安全性进行了仿真分析，通过整车正面100%碰撞仿真结果中各部件吸能量在总能量中所占的比重划分了非安全相关零件和正面碰撞安全相关零件。最终与实车白车身刚度与模态试验以及整车碰撞试验结果进行对比，以此证明了本文所建白车身参数化模型的准确性。
进行了白车身低阶固有频率以及弯曲和扭转刚度的灵敏度分析，并对难以进行灵敏度分析的车身梁结构形状变量以及安全相关性能进行了贡献度分析，以作为灵敏度分析的代替。确定了主要用于减重的对车身性能不敏感但对减重较敏感的板厚和形状设计变量以及主要用于性能弥补的板厚设计变量，为车身结构多目标轻量化优化设计提供基础。
根据实际情况，通过对车身非安全件和安全件轻量化优化设计两个步骤完成整个白车身的轻量化优化设计。
以白车身质量和刚度为目标，低阶固有频率为约束进行了白车身非安全件零件厚度的多目标优化设计，优化采用了NSGA-II方法进行了直接优化设计，最终从得到的非劣解前沿中根据偏好选取出最终解。
在进行了非安全件轻量化优化设计的基础上，以白车身质量和整车正面碰撞的乘员舱加速度峰值为目标，白车身固有频率和刚度以及一些正面碰撞安全性的相关参数为约束进行了关于安全件零件厚度和形状变量的多目标优化设计。此优化为间接优化设计，通过椭圆基函数神经网络方法得到近似模型，利用该近似模型进行多目标轻量化优化设计。
进行了两个阶段的轻量化优化设计后，整个白车身的质量由326.22kg降低到了292.95kg，减重效果十分明显，同时该白车身各项性能没有较大的变化，虽然有些性能有小幅降低，但降幅均在7%之内，轻量化系数由初始模型的4.49变化为4.33，结果表明，本文所进行的轻量化优化取得了很好的效果。
With the rapid development of the automotive industry, the car ownership increasedsignificantly in worldwide. The vehicle had played a huge role in human life and economicsphere. The growing influence changed people's life and work. But with the high-speedincreasing in car ownership of the world, it was influenced the energy, the environment andthe traffic safety enormous. Although electric cars was the best solution, at actual technologylevel, any other method could not be more economic than fossil fuel. As for conventionalfuels for cars. Current vehicle research was developing in high efficiency, low energyconsumption and low emissions, which were all close to vehicle quality. So, the vehiclelightweight was most effective ways to reduce the fuel consumption and emissions atpresent.
The body was an important part of the whole vehicle.Most of the vehicle body weremake up of stamping parts, which had a complex structure and was composed of many parts.is an important part of whole. Its expense occupy almost60%of the investment cost. Thebody mass occupy about30-40%of the whole vehicle. In no-live load condition, about70%of the vehicle’s gas consumption was expended on the vehicle body. Therefore, the bodylightweight was important to the vehicle lightweight, also it was one of the main researchsubjects in vehicle industry.
The research was developed based on the project “research on the body parameterizedlightweight design technology and its integrated application on the target models”which wasa part of the National Twelfth five-year Science and Technology Support Program “R&D ofthe key lightweight technology and integrated application on the car”. As a Chinese car wasthe research object, using implicit parameterization software SFE-concept, respectivelyestablished the car body geometry structures such as engine class, floor and side wall. Assembly relationship among the structures were established by using mapping rmethod.Composing three-dimensional solid BIW parameterization model, then, export. the FEMmodel in SFE-concept.
Getting the initial parameterization FEM model, then, the mode and stiffness analysiswere carried out. Based on the BIW model, the whole car was built and the car crashanalysis was carried out. According to the ratio of each parts’ energy absorption to the wholecar’s energy absorption in100%frontal crash of the car, the safety related parts and thenon-safety related parts were distinguished. All of the analysis results were compared withthe experiment. Through the comparison results, the accuracy of the BIW parameterizationmodel was proved.
The sensitivity analysis of the mode and stiffness were carried out. Because the shapevariables and the safety performance were hard to calculate the sensitivity, the relativityanalysis was used instead of the sensitivity analysis. Finally, the variables which were usedfor reducing the body mass and supplementing the performance were determined. Thosevariables were groundwork for the Multi-objective lightweight optimization design.
According to the actual situation, The BIW multi-objective lightweight optimizationdesign was divided into two parts. One was non-safety parts lightweight optimization design,the other was safety parts lightweight optimization design.
As the mass and stiffness of the BIW were the targets, the lower-order naturalfrequency was the constraint, the non-safety parts lightweight optimization design wascarried out. The NSGA-II method was utilized in the optimization. Finally, according to thepreference, the ultimate solution was selected in the Pareto frontier.
Based on the result of non-safety parts lightweight optimization design, the non-safetyparts lightweight optimization design was carried out, in which the mass and the cabinacceleration peak as the targets and the mode, stiffness and the other safety performences asthe constraints. The optimization was indirect. An approximate model was established byusing the EBFNN method, which was utilized in the multi-objective lightweightoptimization design.
After the two optimization process, the mass of the BIW was reduced from326.22kg to292.95kg. The lightweight effect was very obviously, while the performences of the BIWwere changed less Simultaneously. Although some of the performance were less reduced,those reduction were within7%. The lightweight coefficient was reduced from4.49to4.33.The results indicated that the optimization obtained a very well effect.
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