目的 针对赛车悬架摇臂轻量化的设计需求,分析Octet、Kelvin、Fluorite、Diamond、Schwarz、Gyroid 6种点阵结构单元在不同工况条件下的力学性能,为轻量化设计筛选出合适的点阵结构。方法 利用nTopology软件完成6个阵列晶格结构单元构建,并将孔隙率设置为50%。采用有限元分析方法,控制6种结构网格划分相同,比较分析它们在4 kN载荷、4种工况（拉伸、压缩、扭转和弯曲）下的位移和应力性能。结果 在压缩与弯曲工况下,Schwarz晶格位移（0.013 3 mm、0.025 mm）和应力（128.10 MPa、256.96 MPa）表现较优,应用于赛车悬架摇臂后,通过镂空设计去除冗余材料,体积由424 236.70 mm3缩减至269 888.33 mm3,质量从1.192 kg下降到0.758 kg,比强度提升约57.3%。赛车悬架摇臂所受最大应力为38.62 MPa,远低于赛车悬架摇臂高安全系数下最大应力251.5 MPa,最大位移为0.27 mm,远低于赛车悬架摇臂高安全系数下的位移阈值1.155 mm,最大应变仅0.05%,远低于高安全系数下极限应变0.35%,材料未进入塑性变形阶段,安全裕度充足。结论 将Schwarz晶格应用于赛车悬架摇臂后,轻量化显著且安全裕度充足,进一步拓展了点阵结构在汽车工程中的应用场景,尤其是对承受复合载荷的关键部件具有借鉴价值,为汽车零部件轻量化设计提供了创新解决方案。
Abstract
The work aims to analyze the mechanical properties of six lattice structure units (Octet, Kelvin, Fluorite, Diamond, Schwarz, and Gyroid) under different working conditions, and screen out the optimal lattice structure for lightweight design so as to address the lightweight design requirements of racing car suspension rocker arms. The six array lattice structure units were constructed using nTopology software with a porosity set to 50%. Finite element analysis was employed, with consistent mesh division for all six structures. Their displacement and stress performances were compared under four working conditions (tension, compression, torsion, and bending) with a 4 kN load. Under compression and bending conditions, the Schwarz lattice exhibited the optimal displacement (0.013 3 mm, 0.025 mm) and stress (128.10 MPa, 256.96 MPa). When applied to the racing car suspension rocker arm, the redundant materials were removed through hollow design, resulting in a reduction in volume from 424 236.70 mm3 to 269 888.33 mm3, a decrease in mass from 1.192 kg to 0.758 kg, and an increase in specific strength by approximately 57.3%. The maximum stress of the racing car suspension rocker arm was 38.62 MPa, which was much lower than the maximum stress of 251.5 MPa under high safety factor; the maximum displacement was 0.27 mm, far below the displacement threshold of 1.155 mm under high safety factor; the maximum strain was only 0.05%, significantly lower than the ultimate strain of 0.35% under high safety factors. The material did not enter the plastic deformation stage, indicating sufficient safety margin. The application of the Schwarz lattice in racing car suspension rocker arms achieves significant lightweighting with sufficient safety margin, further expanding the application scenarios of lattice structures in automotive engineering. It is particularly valuable for key components subject to complex loads, providing an innovative solution for the lightweight design of automotive parts.
关键词
3D打印 /
点阵结构 /
力学性能 /
轻量化设计 /
有限元分析
Key words
3D printing /
lattice structure /
mechanical properties /
lightweight design /
finite element analysis
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基金
汽车动力传动与电子控制湖北省重点实验室开放基金（ZDK12023B06）; 湖北省自然科学基金创新发展联合基金重点项目（2024AFD093）; 湖北省教育厅重点项目（D20221801）; 武当人才计划科技领军人才项目（WDREJH- KJLJRC20231）
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