车身大型一体压铸构件轻量化设计方法

doi:10.3901/JME.260247

摘要/Abstract

摘要： 在汽车轻量化技术领域，大型压铸构件因其一体化特征和涉及多学科交叉问题而备受关注，系统性建立针对这类大型压铸构件的轻量化设计方法，以实现多学科性能约束下的全局轻量化设计。针对不存在自然边界的连续车体结构，提出一种兼顾碰撞非线性特征的子系统划分策略，并通过模型降阶技术在确保分析精度的条件下，显著提高计算效率。采用折衷规划法对静态和动态性能目标进行归一化，并构建综合目标函数；提出一种基于初始设计状态性能信息的客观决策序列计算方法，结合层次分析法确定主客观组合赋权的子目标综合权重系数，通过开展拓扑优化，有效指导加强肋的设计。定义适用于压铸件变厚度结构的参数化方法，基于相对灵敏度、熵权法和优劣解距离法(Technique for order preference by similarity to ideal solution, TOPSIS)筛选出对性能影响较大的关键厚度变量。基于最优代理模型，利用差分进化算法开展优化并完成厚度参数设计，最终的工程化方案满足多学科性能并达成全局轻量化，实现减重5.0 kg。所提出的一体压铸构件轻量化方法可为复杂系统模型降阶、大型压铸构件优化设计提供理论与实践依据。

关键词: 一体压铸, 模型降阶, 拓扑优化, 代理模型, 参数设计, 轻量化

Abstract: In the field of vehicle lightweight design, mega-casting components have attracted significant attention due to integrated characteristics and involvement of multidisciplinary issues. Lightweight design methodology for such mega-casting components to achieve global lightweight design under multidisciplinary performance constraints is systematically established. For continuous body structures without natural boundaries, a subsystem partitioning strategy that considers the nonlinear characteristics of collisions is proposed, and model reduction techniques are employed to significantly improve computational efficiency while ensuring analysis accuracy. A compromise programming approach is used to normalize static and dynamic performance objectives and construct a comprehensive objective function. An objective decision sequence calculation method based on the performance information of the initial design state is proposed, which combines the Analytic Hierarchy Process to determine the subjective and objective combined weighting coefficients for sub-objective synthesis, and guides the design of strengthening rib effectively with topology optimization technology. A parameterized method was developed for casting components with variable thickness structures, and key thickness variables affecting multiple properties were identified through relative sensitivity analysis and the entropy-weighted TOPSIS method. The best surrogate model was selected to conduct optimization using the differential evolution algorithm, achieving a balanced approach to multi-disciplinary performance and global lightweight. The weight was reduced by a total of 5.0 kg. The lightweight method offers a robust theoretical and practical foundation, which is useful for reducing complex system models and optimizing the design of mega-casting components.

Key words: mega-casting, model reduction, topology optimization, surrogate model, parameter design, lightweight

中图分类号:

U271

苏永雷, 尹道志, 张志飞, 丁智. 车身大型一体压铸构件轻量化设计方法[J]. 机械工程学报, 2026, 62(5): 306-318.

SU Yonglei, YIN Daozhi, ZHANG Zhifei, DING Zhi. Lightweight Design Method for Vehicle Body Mega-casting Components[J]. Journal of Mechanical Engineering, 2026, 62(5): 306-318.

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链接本文: http://www.cjmenet.com.cn/CN/10.3901/JME.260247

http://www.cjmenet.com.cn/CN/Y2026/V62/I5/306

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