管件液壓汽車扭力樑設計之研究

A Study on Tube-Hydroformed Automotive Twist Beam Design

葉政廷(Cheng-Ting Yeh)

指導教授 ： 陳復國

國立臺灣大學/工學院/機械工程學研究所/碩士(2018年)

https://doi.org/10.6342/NTU201803628

摘要

隨著汽車產業追求節能減碳或汽車電氣化，以管件液壓成形技術取代傳統沖壓技術為有效之方法。在扭力樑設計中沖壓件扭力樑由各部件所組成，故於設計時較容易掌控結構之性質，然而管件液壓件扭力樑為一體成形之結構，各區段之截面皆會互相影響造成設計上之難度。過去研究多針對扭力樑中央Ｖ形截面進行討論，而本論文設計20個幾何參數將液壓件扭力樑整體結構參數化，探討各參數對於液壓件扭力樑之滾動剛性、受力後之應力分佈以及其成形性，並依照扭力樑結構各區段之獨立性及設計之順暢程度建立一套液壓件扭力樑之設計流程。藉由控制單一參數設計不同之扭力樑結構，並以電腦輔助分析可得到其參數對於結構之影響趨勢，依其趨勢更有效率的掌握結構性質。本論文係針對液壓件扭力樑過渡區之曲面進行優化，整理出於過渡區不同類型之應力分佈型態，及其最大應力趨勢且提出控制方式以降低最大應力。
　　本論文探討管件液壓製程預成形模面設計、芯棒設計及模具行程，由此方式可調降管件液壓製程之最終脹形壓力及開模後之殘留應力，最後本論文將扭力樑由沖壓件改為液壓件，其重量減輕約37.5%，最大應力約減小9.5%，且將扭力樑實體載具與有限元素模型進行驗證，確保模擬之準確性。

關鍵字

扭力樑 ； 結構設計及優化 ； 管件液壓成形 ； 預成形 ； 殘留應力

並列摘要

As the automotive industry pursues carbon reduction or automotive electrification, it is an effective method to replace traditional stamping technology with hydroforming technology. The stamped part of the twist beam is composed of various components, so it is easier to control the performance of the structure during design. However, the hydraulic part of the twist beam is a one-piece structure, and the interaction between sections may cause difficulty in design. In the past, the research focused on the central V-shaped section of the twist beam. In this paper, 20 geometric parameters were designed to parameterize the overall structure of the hydraulic part of the twist beam. It discussed effect of parameters on rolling stiffness, the distribution of stress and its formability, and according to the independence of each section of the twist beam structure and the smoothness of the design, a design process of a hydraulic part of the twist beam is established. By controlling a single parameter to design different twist beam structures, and computer-aided analysis can obtain the influence of its parameters on the structure, it can control the structural performance more efficiently according to its trend. This paper optimizes the surface of the transition zone of the hydraulic part of the twist beam, organizes the different types of stress distribution patterns in the transition zone, the maximum stress trend and proposes a control mode to reduce the maximum stress.
　　This paper discusses the design of pre-formed die surface, mandrel design and die stroke of the hydraulic process. In this way, the final forming pressure of the hydraulic process and the residual stress after the die-opening are adjusted. Finally, the paper will make the twist beam from the stamping part changed into hydraulic part. The weight is reduced by about 37.5%, the maximum stress is reduced by about 9.5%. The actual twist beam and the finite element model are verified to ensure the accuracy of the simulation.

並列關鍵字

twist beam ； structure design and optimization ； tube-hydroforming ； pre-forming ； residual stress

參考文獻

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