基于实测的车轮虚拟试验台搭建及参数修正

为了提高某A级车平台轮毂的性能,车轮的设计过程中要通过台架试验来确保产品符合结构耐久性的要求.尝试通过搭建虚拟试验台来快速预测台架上车轮应力状态,以台架试验贴片应变仿真为研究内容,将实际台架试验与数值实验分析相结合,考虑多种因素对仿真结果的影响,如螺栓紧固力大小、球面螺栓和轮辐接触面的相互作用、焊缝的模拟、轮辋和轮辐之间的装配过盈量、加载轴刚度、冲压工艺等参数,进行不同方案的对比分析.扫描轮辋和轮辐的三维尺寸,测量冲压工艺使轮辐产生的厚度变化,修正有限元模型的参数使仿真应变输出与实测应变输出更相近,从而更准确地模拟台架试验,初步搭建了车轮的虚拟试验台.

Construction and Parameters Correction of Wheel Virtual Test Bench Based on Measurement

In order to improve the wheel performance of a class A car platform， the design process should be fit for the structure durable requirements through the bench tests. A virtual test bench was built to predict rapidly the wheel stress on the bench. The strain test of bench was compared with the simulation considering the effects of various influencing factors such as the bolt preload value， the interaction of contact area of spherical bolt and spoke， weld simulation， assembly surplus between the wheel rim and spokes， loading axis stiffness， stamping process， etc. Different schemes were all analyzed. The size of wheel rim and spokes was scanned. The thickness change of the stamping process to produce spokes was measured. The finite element model parameters were modified to make the simulation strain output more similar to the measured ones， and thus more accurate bench test simulation was established.