基于拓扑优化的塑料尾门设计

2023年9月8日 浏览：1671 评论：1 收藏：7


轻量化是汽车结构设计中永恒的话题，不仅传统的燃油车要考虑燃油经济型，要考虑碳排放是否超标，新能源汽车出于对续航里程的考虑也必须将轻量化做到极致。在这样的背景下，对汽车所用材料的研究就变得炙手可热，铝合金发盖、碳纤维车身、塑料尾门等一系列的产品便应运而生了。从第一款自主品牌配置塑料尾门的车型--荣威E50电动车2012年底上市，至2018上市的荣威Marvel X和2020年上市的荣威Marvel R等车型，塑料尾门的应用越来越广泛。

基于拓扑优化的塑料尾门设计的图1

基于拓扑优化的塑料尾门设计的图2

图1 荣威E50（左）荣威Marvel X（右）的塑料尾门

01

塑料尾门的应用

使用塑料尾门首先要考虑的就是是否满足汽车安全性的要求。消费者在认知上可能会以为在追尾事故中尾门要像侧门那样承担吸能和缓冲作用，以抵挡乘员舱的变形，事实上在尾撞中主要由后防撞梁和后纵梁吸收碰撞的能量，上车体E柱和尾门对尾撞的安全性影响甚微。因此，从安全性的角度出发，使用塑料尾门是可行的。
其次是塑料尾门的生产制造工艺。塑料尾门一般内板、外板、扰流板采用PP+LGF、SMC、GMT等树脂材料，而铰链、锁扣及其加强板等采用钣金材料组成。内外板和扰流板采用注塑工艺，镶嵌铰链、锁扣等加强板一体成型。可以将钣金尾门150余个零件减少为70个左右，内外板之间通过聚氨酯胶进行粘接。目前塑料尾门的工艺已经比较成熟，生产节拍甚至要优于钣金尾门。
基于拓扑优化的塑料尾门设计的图3
图2 金属材质和树脂材质零件对比

02

拓扑优化的基本理论

如何设计一款符合工艺和性能等多种指标的塑料尾门呢？拓扑优化不失为一种高效的手段。拓扑优化是在指定的优化空间内，考虑性能、工艺等多种约束和性能指标，对材料分布进行的结构优化，特别适用于铸件类的结构设计。拓扑优化基于SIMP（Solid Isotropic Material with Punishment）理论，即基于带惩罚的实体各向同性材料理论，引入一种假想密度为０～１的材料，用来表示材料的有无，假定材料的宏观弹性常量和密度成非线性关系，优化过程中以单元密度决定单元的去留，采用惩罚因子约束抑制介于０～１之间的单元，通过设置优化目标对构进行拓扑优化。
对于单目标优化问题，常用的拓扑优化数学模型为：

  1. 约束全局或局部的质量或体积，以柔度最小作为目标（刚度的逆为柔度，一般将刚度最大问题转化为柔度最小问题）；

  2. 约束变形量，以质量分数或体积分数最小作为目标；

  3. 约束质量分数或体积分数，以模态频率最大作为目标；

  4. 约束模态频率，以质量分数或体积分数最小作为目标；

其中，质量分数是指优化后的质量与拓扑空间的质量比值，体积分数是指优化后的体积与整个拓扑空间的体积比值。
对于多目标优化问题，可以通过将次要目标转换为约束，从而将多目标优化问题转化为单目标优化问题进行求解；也可以使用线性加权法根据目标的重要程度乘以权重系数然后相加，得到一个组合的目标，或者采用折衷优化法把多个子目标合成一个单目标，对子目标进行归一化处理，然后根据设计需要给每个子目标加上权重。对于一般的问题可直接将目标转换为约束进行拓扑优化，本文也主要采取这种方法。

03

如何使用Optistruct进行拓扑优化

针对塑料尾门的拓扑优化问题，首先要梳理约束和目标，由于Optistruct对线性优化问题的支持比较成熟，因此一般选用线性的工况或将非线性的工况合理简化为线性工况，本文中选用一阶自由模态、扭转和弯曲三个工况作为优化的目标。
设计变量（DesignVariables）：拓扑优化的设计空间根据外造型和内部密封面等的限制来包络一个封闭的空间，并用实体网格填充，将该材料的属性设置为拓扑优化的空间后，会使用SIMP的方法中引入的假想材料密度进行优化。考虑到尾门设计一般是对称的结构，因此需在设计变量中加入对称的约束（PATRN）；此外，可以通过设置最小成员尺寸（MINDIM）约束优化结果中密度为1的区域所允许的最小尺寸，从而消除细小的路径，设置最大成员尺寸（MAXDIM）约束优化结果中密度为1的区域不能全大于的最大尺寸，从而避免材料的过度堆积；根据需要，可以选择拔模参数（DRAW）设置单个模具或两个模具及其拔模方向和角度，从而得到更加真实可行的优化解，塑料尾门是注塑的工艺，根据生产的工艺需求设置合理的拔模深度、拔模角度和分型面。

基于拓扑优化的塑料尾门设计的图4

基于拓扑优化的塑料尾门设计的图5

图3 实体填充的优化空间

约束（OptimizationConstraints）：将多目标优化的目标转换为约束，约束一阶模态大于性能目标值，扭转工况下的监测点变形量小于目标值，弯曲工况下的监测点变形量小于目标值。
目标（Objectives）：目标为体积分数最小。

04

拓扑优化结果及解读

通过合理设置约束，得到最终的拓扑优化结果如图所示：

基于拓扑优化的塑料尾门设计的图6

基于拓扑优化的塑料尾门设计的图7
图4 拓扑优化结果

根据拓扑优化的结果，结合以往车型的设计经验，以及设计变量中无法体现的边界约束如电机和线束的布置空间等，可以对拓扑的结果进行如下的解读：
解读一：“业”字型

基于拓扑优化的塑料尾门设计的图8

图5 “业”字型解读

解读二：双“X”型

基于拓扑优化的塑料尾门设计的图9

图6 双“X”型解读

解读三：W型

基于拓扑优化的塑料尾门设计的图10

图7 W型解读

对解读出来的拓扑结构进行建模，并综合考虑质量、模态、扭转刚度、弯曲刚度等，双X型综合指标最优，结合对标车型如Range Rover Evoque，可见双X型结构的可行性最高。

基于拓扑优化的塑料尾门设计的图11

图8 RangeRover Evoque内板拓扑对标（图片来源于A2Mac1，侵权删）

05

结语

塑料尾门的应用不仅能做到轻量化，还有生产效率高，造型美观且设计的自由度高等特点，满足尾门使用过程中频繁开启的需求，能做到实用和美观并重。虽然目前塑料尾门的成本还比较高，但随着材料和工艺的进一步发展以及越来越广泛的应用，相信在更加成熟的配套体系下还能进一步挖掘以塑代钢的潜力。
       拓扑优化对于早期概念设计阶段有很大的指导意义，能在给定的设计约束下得到初版的拓扑路径，提升设计效率。但是目前受制于实体网格精度，以及拓扑优化方法的局限性，得到的路径不够直观，无法直接输出可行的结构设计方案，因此依赖于工程师的解读。拓扑路径的解读时还需加入未能考虑到的约束，根据以往参考车型来进行，从而可以使初版结构的性能更可靠。随着拓扑优化方法的进一步发展，如薄板结构的加强筋自适应成长设计法等方法的诞生，拓扑优化会发挥出越来越重要的作用。
文章来源上汽安全与CAE技术
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