【作者】 曾云波； 赵凯阳； 林兆富； 徐慧； 马薇； 刘波； 杨健； 唐晓亮；

【Author】 Zeng Yunbo;Zhao Kaiyang;Lin Zhaofu;Xu Hui;Ma Wei;Liu Bo;Yang Jian;Tang Xiaoliang;Chongqing Changan Automobile Co.,Ltd.;University of Science and Technology Beijing,School of Mechanical Engineering;Chenzhi Technology Co.,Ltd.;

【机构】 重庆长安汽车股份有限公司； 北京科技大学； 辰致科技有限公司；

【摘要】 铝合金Giga-Casting在汽车车体轻量化、集成化和平台化面具有巨大的潜力。但Giga-Casting结构设计、工艺模具、性能目标、尺寸精度以及装车匹配与传统钢车身完全不同,且可参考经验与记录较少。本文以汽车主机厂实际开发案例,介绍铝合金Giga-Casting前机舱的全流程开发流程,包括正向集成设计、材料选择、仿真分析、模具设计、生产制造和试验验证,旨在提升Giga-Casting在汽车行业应用信心与动力。通过全流程分析,将传统的73个零件集成为一个零件,减重13.6kg,减重率约20.6%。前机舱整体抗拉强度平均值257.1MPa,屈服强度平均值122.49MPa,延伸率平均值为8.05%。同时达成白车身连接、性能和尺寸精度目标。该研究大大提升自主汽车品牌形象,在突破大型压铸铝合金零件缺陷控制技术上具有广阔前景。更多还原

【Abstract】 Aluminum Giga-Casting has enormous potential for automotive body lightweighting,integration and platformization.However,Giga-Casting structural design,process tooling,performance targets,dimensional accuracy,and vehicle fitment are completely different from conventional steel bodies,and there is less experience and records to refer to.This paper introduces the whole process development flow of aluminum alloy Giga-Casting front nacelle,including forward integration design,material selection,simulation analysis,tooling design,manufacturing,and test validation,with the actual development cases of automobile OEMs,aiming to enhance the confidence and motivation of the application of Giga-Casting in the automobile industry.By analyzing the whole process,the traditional73 parts are integrated into one part,and the weight is reduced by 13.6 kg,which is about 20.6%.The overall tensile strength of the front nacelle averaged 257.1 MPa,the yield strength averaged 122.49 MPa,and the elongation averaged 8.05%.Meanwhile,the body-in-white connection,performance and dimensional accuracy targets are met.This research greatly enhances the brand identity of independent cars,and has a broad prospect in breaking through the defect control technology of large die-casting aluminum alloy parts.更多还原