Optimization method and system for durability simulation analysis of trailer lever platform
By constructing a durability simulation analysis model of the trailer bumper bench and a weld SN curve function, and adjusting the weld connection method to bolt connection, the problem of weld cracking in traditional simulation analysis methods was solved, and the durability performance of the trailer bumper was improved.
Patent Information
- Application Number
- CN202310111388.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- Filing Date
- 2023-02-09
- Publication Date
- 2026-02-17
- Estimated Expiration
- 2043-02-09
AI Technical Summary
Traditional simulation analysis methods lack accuracy in assessing the durability of trailer bar welds, resulting in simulation results that cannot accurately match actual conditions, leading to weld cracking, affecting experimental progress and wasting resources.
A durability simulation analysis model of the trailer bumper frame was constructed to obtain the stress distribution in the weld area, a weld SN curve function was constructed, and the weld connection method was adjusted to bolt connection to reduce the stress level.
Effectively assess the maximum allowable stress amplitude in the weld area, and improve the weld durability cycle life through structural and process optimization to meet the bench durability cycle requirements.
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Figure CN116341098B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of trailer boom simulation analysis technology, and in particular to a method and system for optimizing trailer boom bench durability simulation analysis. Background Technology
[0002] As per capita household income and consumption capacity continue to rise in my country, domestic car sales are showing a sustained upward trend. Against this backdrop, personalized demands are becoming increasingly apparent; among these, towable caravans, with their large independent storage space capable of accommodating various large items (such as beds, sofas, bicycles, etc.), are seeing a continuous increase in usage by households. Towable caravans are connected to a towing vehicle (car, SUV, pickup truck, etc.) via a trailer hitch, which then propels the caravan through the trailer hitch; therefore, the trailer hitch is a crucial force-transmitting component. Due to the continuously increasing demand for family travel (increased duration and frequency), an improperly designed trailer hitch, resulting in insufficient durability (failure, cracking, or breakage within a short period of use), will cause significant inconvenience to family travel. Trailer failure not only affects users' travel mindset but also causes time and financial losses for vehicle use. In more extreme cases (such as during a long-distance trip on the Sichuan-Tibet Highway, where the trailer bumper fails midway), it may even threaten personal safety. Therefore, simulation evaluation and optimization design of the trailer bumper are extremely important during the overall vehicle development process. Through simulation analysis, the simulation results provide reference and optimization guidance for the vehicle body design, ensuring that the optimized trailer bumper structure can guarantee that the trailer bumper will not crack or break under the specified bench durability cycle.
[0003] The durability cracking issues observed in trailer bumpers during bench testing primarily stemmed from cracking in the weld area. In durability simulation evaluations of trailer bumpers, traditional simulation analysis methods mainly rely on the material numeric index (SN) databases provided by commercial durability software. Therefore, the weld SN curve is a crucial parameter for durability life information. However, because welds are heterogeneous materials (the material composition and micrograin size vary across different areas of the weld), and different automotive OEMs possess varying welding equipment, welding process parameters, and welding materials, directly referencing the SN curves from commercial durability software when evaluating weld durability life results in poor matching between simulation and experimental results. In other words, after determining the required durability cycle number (N) for the weld, the maximum allowable stress amplitude obtained through simulation calculations differs from the maximum allowable stress amplitude in actual testing. Therefore, the accuracy of the weld material parameters provided by commercial software is insufficient to match the actual weld material parameters, resulting in the simulation results failing to provide design guidance for subsequent testing.
[0004] As the above analysis shows, due to the insufficient accuracy of traditional weld simulation analysis methods, directly using the weld SN curve from commercial durability software cannot match the material parameters of the actual weld, causing weld cracking in the trailer bar during durability testing, affecting the experimental progress, and wasting experimental resources and funds. Therefore, it is necessary to design a scheme to evaluate the maximum allowable stress amplitude in the weld area of the trailer bar structure, and based on the stress distribution of the weld in the analysis results, optimize the structure and process of local high-stress areas to reduce the stress level in the high-stress areas of the weld (making it less than the maximum allowable stress amplitude in the weld area), thereby improving the durability cycle life of the trailer bar weld and meeting the durability cycle requirements of the trailer bar test bench. Summary of the Invention
[0005] The present invention provides a method and system for durability simulation analysis and optimization of trailer boom frame, which reduces the stress level in the weld area by retaining only the necessary connection function between parts, thereby enabling the trailer boom to meet the durability cycle requirements of the frame.
[0006] Firstly, a method for durability simulation analysis and optimization of a trailer boom test bench is provided, including the following steps:
[0007] The number of durability cycles corresponding to the appearance of cracks in the weld area of the trailer bumper was obtained in the bench durability test.
[0008] Based on the durability test conditions of the trailer bar bench, a durability simulation analysis model and working conditions of the trailer bar bench are constructed. The Hyperworks post-processing software is called to perform simulation analysis to obtain the stress distribution state of the trailer bar weld area and the stress amplitude at the corresponding position when cracks appear in the trailer bar weld area during the bench durability test.
[0009] Based on the number of durability cycles corresponding to the occurrence of cracks in the trailer bar weld area and the stress amplitude, a trailer bar weld SN curve function is constructed, and the maximum stress amplitude corresponding to the trailer bar weld area is obtained based on the trailer bar weld SN curve function.
[0010] Based on the stress distribution of the trailer bumper, identify the areas of the trailer bumper welds that exceed the maximum stress amplitude, and adjust the connection method of the trailer bumper weld areas to bolt connection based on the areas of the trailer bumper welds that exceed the maximum stress amplitude.
[0011] According to the first aspect, in the first possible implementation of the first aspect, the step of "constructing a trailer boom bench durability simulation analysis model based on the trailer boom bench durability test state" specifically includes the following steps:
[0012] Acquire trailer bar data that is consistent with the durability test conditions of the trailer bar bench, wherein the trailer bar data includes CAD data and material information data;
[0013] A finite element simulation analysis model of the trailer bumper was constructed based on the CAD data.
[0014] The material properties of the trailer bar finite element simulation analysis model are assigned based on the material information data to obtain the trailer bar bench durability simulation analysis model.
[0015] According to the first possible implementation of the first aspect, in the second possible implementation of the first aspect, the step of "constructing the durability simulation analysis conditions of the trailer boom bench" specifically includes the following steps:
[0016] In the durability simulation analysis model of the trailer boom bench, the degrees of freedom of the bolt holes on the mounting plates on both sides of the trailer boom are constrained, and an external load consistent with the durability test of the trailer boom bench is applied at the ball head position of the trailer hook.
[0017] According to the second possible implementation of the first aspect, in the third possible implementation of the first aspect, the step of "constructing the stress amplitude of the trailer bar weld SN curve function based on the number of durability cycles corresponding to the occurrence of cracks in the trailer bar weld area and the stress amplitude" specifically includes the following steps:
[0018] The SN curve function for the trailer bumper weld is as follows:
[0019] log N+2.734027 log S=log(7.19 302*10 11 );
[0020] In the formula, N is the number of durability cycles; S is the stress amplitude.
[0021] According to the third possible implementation of the first aspect, in the fourth possible implementation of the first aspect, the step of "obtaining the maximum stress amplitude corresponding to the trailer bar weld area according to the SN curve function of the trailer bar weld" specifically includes the following steps:
[0022] Based on the SN curve function of the trailer bar weld, the maximum stress amplitude corresponding to the trailer bar weld area under the preset target durability cycle number and the preset safety constraint condition is obtained.
[0023] Secondly, a durability simulation analysis and optimization system for a trailer boom test bench is provided, including:
[0024] The bench durability test module is used to obtain the number of durability cycles corresponding to the appearance of cracks in the weld area of the trailer bumper during bench durability testing.
[0025] The bench durability simulation analysis module is communicatively connected to the bench durability test module. It is used to construct a trailer bar bench durability simulation analysis model and a trailer bar bench durability simulation analysis working condition based on the trailer bar bench durability test state; and to call the Hyperworks post-processing software to perform simulation analysis, obtain the stress distribution state of the trailer bar weld area and the stress amplitude at the corresponding position when cracks appear in the trailer bar weld area during the bench durability test.
[0026] The SN curve function construction module is communicatively connected to the bench durability test module and the bench durability simulation analysis module. It is used to construct the SN curve function of the trailer bar weld according to the number of durability cycles and the stress amplitude when cracks appear in the weld area of the trailer bar, and to obtain the maximum stress amplitude corresponding to the weld area of the trailer bar according to the SN curve function of the trailer bar weld.
[0027] The connection adjustment module is communicatively connected to the bench durability simulation analysis module and the SN curve function construction module. It is used to obtain the excessive area of the trailer bar weld that exceeds the maximum stress amplitude according to the stress distribution state of the trailer bar, and adjust the connection method of the trailer bar weld area to bolt connection according to the excessive area of the weld.
[0028] According to the second aspect, in the first possible implementation of the second aspect, the bench durability simulation analysis module is used to acquire trailer bar data consistent with the durability test state of the trailer bar bench, the trailer bar data including CAD data and material information data; construct a trailer bar finite element simulation analysis model based on the CAD data; assign material property values to the trailer bar finite element simulation analysis model based on the material information data, and obtain the trailer bar bench durability simulation analysis model.
[0029] According to the first possible implementation of the second aspect, in the second possible implementation of the first aspect, the bench durability simulation analysis module is further used to constrain the degrees of freedom of the bolt holes on both sides of the trailer bar mounting plate in the trailer bar bench durability simulation analysis model, and to apply an external load consistent with the trailer bar bench durability test at the trailer hook ball head position.
[0030] According to the second possible implementation of the second aspect, in the third possible implementation of the first aspect, the SN curve function construction module is used for,
[0031] The SN curve function for the trailer bumper weld is as follows:
[0032] log N+2.734027 log S=log(7.19 302*10 11 );
[0033] In the formula, N is the number of durability cycles; S is the stress amplitude.
[0034] According to the third possible implementation of the second aspect, in the fourth possible implementation of the first aspect, the SN curve function construction module is further used to obtain the maximum stress amplitude corresponding to the trailer bar weld area under the preset target durability cycle number and the preset safety constraint condition based on the trailer bar weld SN curve function.
[0035] Compared with the prior art, the advantages of the present invention are as follows: it can effectively evaluate the maximum allowable stress amplitude of the weld area in the trailer bar structure, and based on the stress distribution of the weld in the analysis results, it can release the load-bearing function of the weld by optimizing the structure and process of the local high stress area, so that the weld area only retains the necessary connection function between parts, thereby reducing the stress level of the weld area, so that the trailer bar meets the bench durability cycle requirements. Attached Figure Description
[0036] Figure 1 This is a flowchart illustrating an embodiment of a durability simulation analysis and optimization method for a trailer boom bench according to the present invention;
[0037] Figure 2 This is a schematic diagram showing the number of durability cycles corresponding to the occurrence of cracks in the weld area of the trailer bumper during bench durability testing of the present invention;
[0038] Figure 3 This is a schematic diagram illustrating the adjustment of the connection method of the trailer bar weld area to a bolt connection according to the present invention;
[0039] Figure 4 This is a schematic diagram of the working conditions for the durability simulation analysis of the trailer boom test bench constructed according to the present invention;
[0040] Figure 5 This is a schematic diagram of the stress distribution of the trailer bar of the present invention;
[0041] Figure 6 This is a schematic diagram of the post-processing software analysis results after optimizing the connection method of the trailer bumper weld area;
[0042] Figure 7 This is a flowchart illustrating another embodiment of the durability simulation analysis and optimization method for a trailer boom bench according to the present invention.
[0043] Figure 8 This is a schematic diagram of the structure of a trailer boom bench durability simulation analysis and optimization system according to the present invention. Detailed Implementation
[0044] Referring now to specific embodiments of the invention, examples of which are illustrated in the accompanying drawings. Although the invention will be described in conjunction with specific embodiments, it will be understood that it is not intended to limit the invention to the described embodiments. Rather, it is intended to cover variations, modifications, and equivalents included within the spirit and scope of the invention as defined by the appended claims. It should be noted that the method steps described herein can be implemented by any functional block or functional arrangement, and any functional block or functional arrangement can be implemented as a physical entity or a logical entity, or a combination of both.
[0045] To enable those skilled in the art to better understand the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.
[0046] Note: The examples described below are merely specific examples and are not intended to limit the embodiments of the present invention to the specific steps, values, conditions, data, order, etc. Those skilled in the art can utilize the concept of the present invention to construct more embodiments not mentioned herein by reading this specification.
[0047] See Figure 1 As shown, this embodiment of the invention provides a method for durability simulation analysis and optimization of a trailer bumper bench, including the following steps:
[0048] S100, the number of durability cycles corresponding to the appearance of cracks in the weld area of the trailer bumper during bench durability testing;
[0049] S200, based on the durability test conditions of the trailer bar bench, constructs a durability simulation analysis model and working conditions of the trailer bar bench; calls Hyperworks post-processing software to perform simulation analysis, obtains the stress distribution state of the trailer bar weld area and the stress amplitude at the corresponding position when cracks appear in the trailer bar weld area during the bench durability test.
[0050] S300, based on the number of durability cycles corresponding to the occurrence of cracks in the trailer bar weld area and the stress amplitude, construct the trailer bar weld SN curve function, and obtain the maximum stress amplitude corresponding to the trailer bar weld area based on the trailer bar weld SN curve function.
[0051] S400: Based on the stress distribution of the trailer bumper, identify the weld seam exceeding the maximum stress amplitude area of the trailer bumper, and adjust the connection method of the trailer bumper weld seam area to bolt connection based on the weld seam exceeding the standard area.
[0052] Specifically, in this embodiment, when evaluating the durability of the trailer bumper, it is mainly necessary to perform simulation analysis on two areas: the weld area and the base metal. During the durability simulation evaluation, the SN curves of the weld and the base metal are extremely critical durability information parameters.
[0053] The SN curve refers to the relationship between the stress on a part under symmetrical periodic external load and the maximum number of durability cycles it can withstand without cracking or failure under this stress. Based on the fatigue formula for metallic materials, the specific formula is as follows:
[0054] LogN + mLogS = LogA
[0055] In the formula, N is the number of durability cycles; S is the stress amplitude; m and A are a set of constants that do not change with the external load (as long as the material is determined, they are inherent properties of the material).
[0056] As can be seen from the above formula, once m and A are determined, when conducting bench durability tests, after clearly defining the durability cycle number N that the part needs to meet, the maximum stress amplitude S that the part can withstand can be calculated.
[0057] Since the base metal is a homogeneous material (the material composition and micrograin size are the same in different regions of the base metal), the overall differences between products produced by different material manufacturers are not significant. When evaluating the durability of the base metal, the SN curves of commercial durability software are directly used. The simulation results match the experimental results well (that is, the m-values and A-values of the corresponding base material in the commercial software are basically consistent with the actual material parameters m-values and A-values of the base material in the durability test, with very small differences). In other words, after determining the required number of durability cycles N for the base material, the maximum allowable stress amplitude of the base material obtained through simulation calculation is basically consistent with the maximum allowable stress amplitude of the base material in the actual test. Therefore, the accuracy of the base material parameters (m-values and A-values) in the commercial software is sufficient to match the actual material parameters (m-values and A-values) of the base material, and the preliminary simulation results can provide design guidance for subsequent tests.
[0058] However, because welds are heterogeneous materials (the material composition and micrograin size vary in different regions of the weld), and the welding equipment, welding process parameters, and welding materials possessed by different automotive OEMs vary significantly, directly referencing the SN curves from commercial durability software when evaluating weld durability life results in poor matching between simulation and experimental results. This means that the m-values and A-values of the weld material provided in the commercial software are inconsistent with the actual material parameters (m-values and A-values) of the weld in the durability test, showing a large discrepancy. Specifically, after determining the required number of durability cycles (N) for the weld, the maximum allowable stress amplitude obtained through simulation calculations differs from the maximum allowable stress amplitude in actual testing. In other words, the accuracy of the weld material parameters (m-values and A-values) provided in commercial software is insufficient to match the actual material parameters (m-values and A-values) of the weld, rendering the initial simulation results unsuitable for design guidance in later testing.
[0059] Therefore, based on the above analysis, the vast majority of durability cracking problems that occur in trailer booms during bench testing are weld cracking problems.
[0060] Because traditional weld simulation analysis methods lack accuracy (directly referencing the m and A values from the weld SN curve in commercial durability software cannot match the m and A values in the actual weld material parameters), the initial simulation results cannot provide design guidance for later tests. This results in engineers being unable to provide effective optimization solutions if weld cracks occur in the trailer bumper during durability testing. This significantly impacts experimental progress and wastes experimental resources and funds.
[0061] Therefore, this invention proposes a complete method for durability simulation analysis and optimization of trailer bar test benches. This method can effectively evaluate the maximum allowable stress amplitude in the weld area of the trailer bar structure. Based on the stress distribution in the weld area from the analysis results, the structure and process of the local high-stress areas are optimized (by adjusting the connection method of the trailer bar weld area to bolt connection) to reduce the stress level in the high-stress areas of the weld (making it less than the maximum allowable stress amplitude in the weld area), thereby improving the durability cycle life of the trailer bar weld and meeting the durability cycle requirements of the trailer bar test bench.
[0062] See Figure 2 As shown in S100, the weld area of the trailer bumper (two weld crack locations) is obtained. One weld crack occurs after 350,000 bench durability cycles (referred to as location a), and the other weld crack occurs after 900,000 bench durability cycles (referred to as location b).
[0063] See Figure 3 As shown, S400, based on the stress distribution state of the trailer bumper (see...). Figure 5As shown, the areas of the trailer bumper welds exceeding the maximum stress amplitude were identified, and these areas were all located at critical load-bearing (force-bearing) locations. Therefore, the optimization solution is to release the load-bearing function of the welds, allowing them to retain only the essential connection function between parts. This can be achieved by changing the connection method at critical load-bearing (force-bearing) locations, replacing welding with bolted connections, because the durability of bolted connections is extremely close to that of the base material and far exceeds that of welds.
[0064] By reconstructing the durability simulation analysis model and working conditions of the trailer boom after optimizing the connection method, and calling the Hyperworks post-processing software, the stress amplitude of the trailer boom weld area was calculated to be 76.25 MPa, which is less than the maximum stress amplitude of 89.75 MPa (the specific values are described below), thus meeting the design requirements.
[0065] Preferably, in another embodiment of this application, the step "S200, constructing a trailer bumper bench durability simulation analysis model based on the trailer bumper bench durability test state" specifically includes the following steps:
[0066] S210, Obtain trailer bar data consistent with the durability test state of the trailer bar bench, wherein the trailer bar data includes CAD data and material information data;
[0067] S220, Construct a finite element simulation analysis model of the trailer bumper based on the CAD data;
[0068] S230, Assign material property values to the finite element simulation analysis model of the trailer boom based on the material information data to obtain the durability simulation analysis model of the trailer boom frame.
[0069] Specifically, in this embodiment, trailer bar data consistent with the durability test data of the trailer bar bench is obtained. The trailer bar data includes CAD data and material information data. Based on the CAD data, the metal body of the trailer bar is modeled using 2D shell elements, and the weld seams are also modeled using 2D shell elements with an average element size of 5mm*5mm, thus obtaining a finite element simulation analysis model of the trailer bar. Then, based on the material information table, material and attribute information is assigned to the finite element simulation analysis model of the trailer bar, resulting in a durability simulation analysis model of the trailer bar bench.
[0070] The material information table is shown in Table (I) below.
[0071] 1 square steel Q345 2 Mounting plate DL510 3 Central reinforcement plate HC420L 4 Tow hook mounting plate CP800 5 tow hook 45# steel
[0072] Table (1)
[0073] Preferably, in another embodiment of this application, the step "S200, constructing the trailer boom bench durability simulation analysis conditions" specifically includes the following steps:
[0074] S240, in the durability simulation analysis model of the trailer boom bench, the degrees of freedom of the bolt holes on the mounting plates on both sides of the trailer boom are constrained, and an external load consistent with the durability test of the trailer boom bench is applied at the ball head position of the trailer hook.
[0075] Specifically, in this embodiment, see Figure 4 As shown, the bolt holes (four on each side) of the trailer bumper mounting plates are constrained for 123456 degrees of freedom. Simultaneously, an external load (amplitude 6793 N, at a 20° angle to the horizontal plane) consistent with the trailer bumper bench durability test is applied to the trailer hook ball joint. Therefore, it is necessary to ensure that the constraints and loading states of the trailer bumper bench durability simulation analysis model are completely consistent with the trailer bumper bench durability test. Based on this, Hyperworks post-processing software is used to obtain the stress distribution of the trailer bumper and the stress amplitude at the corresponding location when cracks appear in the trailer bumper weld area during the bench durability test. See [link to relevant documentation]. Figure 5 As shown.
[0076] Preferably, in another embodiment of this application, the step of "S300, constructing the trailer bar weld SN curve function based on the number of durability cycles corresponding to the occurrence of cracks in the trailer bar weld area and the stress amplitude" specifically includes the following steps:
[0077] The SN curve function for the trailer bumper weld is as follows:
[0078] log N+2.734027 log S=log(7.19302*10 11 );
[0079] In the formula, N is the number of durability cycles; S is the stress amplitude.
[0080] Specifically, in this embodiment, the SN curve of the material (whether it is the weld or the base material) satisfies the formula: LogN + mLogS = LogA;
[0081] Based on the two sets of stress-durability cycle count data obtained, as shown in Table (II) below, substituting them into the above formula yields the following formula:
[0082] log N+2.734027 log S=log(7.19 302*10 11 ).
[0083] Serial Number Stress amplitude / MPa Durability cycle count / times Group 1 203.7 350000 2 groups 144.2 900000
[0084] Table (II)
[0085] Preferably, in another embodiment of this application, the step "S300, obtaining the maximum stress amplitude corresponding to the trailer bar weld area based on the SN curve function of the trailer bar weld" specifically includes the following steps:
[0086] Based on the SN curve function of the trailer bar weld, the maximum stress amplitude corresponding to the trailer bar weld area under the preset target durability cycle number and the preset safety constraint condition is obtained.
[0087] Specifically, in this embodiment, the target of the bench durability cycle test is 2 million cycles. Substituting 2 million cycles into the above formula, the maximum allowable stress amplitude corresponding to the weld is obtained as 107.7 MPa. Considering that the weld quality has a certain degree of dispersion, a safety factor of 1.2 (preset safety constraint condition) is taken, and the final maximum allowable stress amplitude corresponding to the weld is 89.75 MPa. Therefore, subsequent optimization of the trailer bar needs to meet the requirement that the maximum stress in the weld area is <89.75 MPa.
[0088] Therefore, by interpreting the original CAD structure of the trailer bumper, all areas of welds with stress exceeding 89.75MPa were identified.
[0089] See Figure 6 As shown, by reconstructing the durability simulation analysis model and working conditions of the trailer boom frame after optimizing the connection method, and calling the Hyperworks post-processing software, the stress amplitude of the trailer boom weld area was calculated to be 76.25 MPa, which is less than the maximum stress amplitude of 89.75 MPa.
[0090] Therefore, the optimized trailer bar bench passed the durability test. This indicates that the entire optimization process (a. constructing the SN curve function formula for the trailer bar weld; b. determining the maximum allowable stress amplitude of the weld; c. designing a new optimized trailer bar structure) was successful and effective.
[0091] See also Figure 7 As shown in the figure, the present invention provides a method for durability simulation analysis and optimization of a trailer boom test bench, the specific steps of which are as follows:
[0092] 1. Record the number of durability cycles corresponding to the occurrence of weld cracks in the trailer bumper during the bench durability test [there are two weld crack locations (referred to as location a: 350,000 weld cracks) and (referred to as location b: 900,000 weld cracks).
[0093] 2. Obtain the CAD data of the trailer boom, which is consistent with the data from the bench test, and its material information table.
[0094] 3. Perform finite element modeling of the trailer bar and assign material property values to the finite element analysis model of the trailer bar to complete the construction of the durability simulation analysis model of the trailer bar bench.
[0095] 4. Create a durability simulation analysis of the trailer boom bench according to the test conditions, and solve the calculation.
[0096] 5. After step 4, obtain the stress distribution state of the trailer bumper in the simulation software; and record the stress amplitude corresponding to the crack positions a and b of the trailer bumper in step 1.
[0097] 6. Based on the durability cycle count and stress obtained from points 1 and 5, construct the SN curve function formula for the trailer bumper and confirm the maximum allowable stress amplitude of the weld.
[0098] 7. Perform stress analysis on the original CAD structural simulation results of the trailer bumper to identify all areas where the stress exceeds the standard in the welds.
[0099] 8. Optimize the structure and connection process of the trailer bar, and adjust the connection method of the trailer bar weld area to bolt connection according to the weld seam exceeding the standard area.
[0100] 9. Solve the calculation for the optimized trailer boom.
[0101] 10. The optimized trailer boom underwent physical bench durability cycle verification, and the optimized trailer boom passed the bench durability test.
[0102] Therefore, the entire optimization process (a. constructing the SN curve function formula for the trailer bar weld; b. determining the maximum stress amplitude that the weld can withstand; c. designing a new optimized trailer bar structure) is successful and effective.
[0103] This method effectively determines the actual m and A values of the weld material parameters. These values are then substituted into the fatigue formula for metallic materials to effectively assess the maximum allowable stress amplitude in the weld area of the trailer bumper structure. Based on the stress distribution in the weld, structural and process optimizations are performed on locally high-stress areas to release the load-bearing function of the weld, ensuring that the weld area retains only the necessary connection function between parts, thereby reducing the stress level in the weld area. This allows the trailer bumper to meet the bench durability cycle requirements.
[0104] See also Figure 8 As shown, this embodiment of the invention also provides a trailer bumper bench durability simulation analysis and optimization system, including:
[0105] The bench durability test module is used to obtain the number of durability cycles corresponding to the appearance of cracks in the weld area of the trailer bumper during bench durability testing.
[0106] The bench durability simulation analysis module is communicatively connected to the bench durability test module. It is used to construct a trailer bar bench durability simulation analysis model and a trailer bar bench durability simulation analysis working condition based on the trailer bar bench durability test state; and to call the Hyperworks post-processing software to perform simulation analysis, obtain the stress distribution state of the trailer bar weld area and the stress amplitude at the corresponding position when cracks appear in the trailer bar weld area during the bench durability test.
[0107] The SN curve function construction module is communicatively connected to the bench durability test module and the bench durability simulation analysis module. It is used to construct the SN curve function of the trailer bar weld according to the number of durability cycles and the stress amplitude when cracks appear in the weld area of the trailer bar, and to obtain the maximum stress amplitude corresponding to the weld area of the trailer bar according to the SN curve function of the trailer bar weld.
[0108] The connection adjustment module is communicatively connected to the bench durability simulation analysis module and the SN curve function construction module. It is used to obtain the excessive area of the trailer bar weld that exceeds the maximum stress amplitude according to the stress distribution state of the trailer bar, and adjust the connection method of the trailer bar weld area to bolt connection according to the excessive area of the weld.
[0109] The bench durability simulation analysis module is used to acquire trailer bar data consistent with the durability test state of the trailer bar bench. The trailer bar data includes CAD data and material information data. A finite element simulation analysis model of the trailer bar is constructed based on the CAD data. Material property values are assigned to the finite element simulation analysis model of the trailer bar based on the material information data to obtain the trailer bar bench durability simulation analysis model.
[0110] The bench durability simulation analysis module is also used to constrain the degrees of freedom of the bolt holes on both sides of the trailer bar mounting plate in the trailer bar bench durability simulation analysis model, and to apply an external load consistent with the trailer bar bench durability test at the trailer hook ball head position.
[0111] The SN curve function construction module is used to construct the SN curve function for the trailer bumper weld as follows:
[0112] log N+2.734027 log S=log(7.19 302*10 11 );
[0113] In the formula, N is the number of durability cycles; S is the stress amplitude.
[0114] The SN curve function construction module is also used to obtain the maximum stress amplitude corresponding to the trailer bar weld area under the preset target durability cycle number and the preset safety constraint condition based on the trailer bar weld SN curve function.
[0115] Therefore, the actual values of m and A in the weld material parameters can be effectively determined. These values are then substituted into the fatigue formula for metallic materials to effectively assess the maximum allowable stress amplitude in the weld area of the trailer bumper structure. Based on the stress distribution in the weld, structural and process optimizations are performed on locally high-stress areas to release the load-bearing function of the weld, ensuring that the weld area retains only the necessary connection function between parts, thereby reducing the stress level in the weld area. This allows the trailer bumper to meet the bench durability cycle requirements.
[0116] Based on the same inventive concept, embodiments of this application also provide a computer-readable storage medium storing a computer program thereon, which, when executed by a processor, implements all or part of the method steps of the above method.
[0117] The present invention can implement all or part of the processes in the above methods, or it can be accomplished by a computer program instructing related hardware. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various method embodiments described above. The computer program includes computer program code, which can be in the form of source code, object code, executable file, or some intermediate form. The computer-readable medium can include: any entity or device capable of carrying computer program code, recording media, USB flash drive, portable hard drive, magnetic disk, optical disk, computer memory, read-only memory (ROM), random access memory (RAM), electrical carrier signals, telecommunication signals, and software distribution media, etc. It should be noted that the content included in the computer-readable medium can be appropriately added or removed according to the requirements of legislation and patent practice in the jurisdiction. For example, in some jurisdictions, according to legislation and patent practice, the computer-readable medium does not include electrical carrier signals and telecommunication signals.
[0118] Based on the same inventive concept, embodiments of this application also provide an electronic device, including a memory and a processor. The memory stores a computer program that runs on the processor. When the processor executes the computer program, it implements all or part of the method steps described above.
[0119] The processor can be a Central Processing Unit (CPU), or other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. A general-purpose processor can be a microprocessor or any conventional processor. The processor is the control center of the computer device, connecting all parts of the computer device through various interfaces and lines.
[0120] Memory can be used to store computer programs and / or modules. The processor performs various functions of the computer device by running or executing the computer programs and / or modules stored in the memory, and by accessing data stored in the memory. Memory can primarily include a program storage area and a data storage area. The program storage area can store the operating system and at least one application program required for a function (e.g., sound playback, image playback, etc.); the data storage area can store data created based on the use of the mobile phone (e.g., audio data, video data, etc.). Furthermore, memory can include high-speed random access memory, and can also include non-volatile memory, such as hard disks, RAM, plug-in hard disks, SmartMedia Cards (SMC), Secure Digital (SD) cards, Flash Cards, at least one disk storage device, flash memory device, or other volatile solid-state storage devices.
[0121] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, servers, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage and optical storage) containing computer-usable program code.
[0122] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), servers, and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.
[0123] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.
[0124] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.
[0125] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.
Claims
1. A method for durability simulation analysis and optimization of a trailer boom test bench, characterized in that, The method comprises the following steps: obtaining the corresponding durability cycle number when the crack appears in the welding seam area of the trailer hanger in the bench durability test; based on the state of the bench durability test of the trailer hanger, constructing a bench durability simulation analysis model and a bench durability simulation analysis condition of the trailer hanger; calling the hyperworks post-processing software to perform simulation analysis, obtaining the stress distribution state of the welding seam area of the trailer hanger and the stress amplitude value of the corresponding position of the welding seam area of the trailer hanger when the crack appears in the bench durability test; according to the corresponding durability cycle number when the crack appears in the welding seam area of the trailer hanger and the stress amplitude value, constructing a SN curve function of the welding seam of the trailer hanger, and obtaining the corresponding maximum stress amplitude value of the welding seam area of the trailer hanger according to the SN curve function of the welding seam of the trailer hanger; according to the stress distribution state of the trailer hanger, obtaining the welding seam exceeding area of the trailer hanger exceeding the maximum stress amplitude value, and adjusting the connection mode of the welding seam area of the trailer hanger to bolt connection according to the welding seam exceeding area; the "based on the state of the bench durability test of the trailer hanger, constructing a bench durability simulation analysis model" step specifically comprises the following steps: obtaining the trailer hanger data consistent with the state of the bench durability test of the trailer hanger, the trailer hanger data comprising CAD data and material information data; constructing a finite element simulation analysis model of the trailer hanger according to the CAD data; assigning material properties to the finite element simulation analysis model of the trailer hanger according to the material information data, and obtaining a bench durability simulation analysis model of the trailer hanger.
2. The trailer rack durability simulation analysis optimization method of claim 1, wherein, the "constructing a bench durability simulation analysis condition of the trailer hanger" step specifically comprises the following steps: in the bench durability simulation analysis model of the trailer hanger, constrain the freedom of the bolt hole of the trailer hanger installation plate on both sides, and apply the external load consistent with the bench durability test of the trailer hanger at the trailer hook ball head position.
3. The trailer rack durability simulation analysis optimization method of claim 1, wherein, the "according to the corresponding durability cycle number when the crack appears in the welding seam area of the trailer hanger and the stress amplitude value, constructing a SN curve function of the welding seam of the trailer hanger" step specifically comprises the following steps: the SN curve function of the welding seam of the trailer hanger is as follows: ； wherein N is the durability cycle number; S is the stress amplitude value.
4. The trailer rack durability simulation analysis optimization method of claim 1, wherein, the "according to the SN curve function of the welding seam of the trailer hanger, obtaining the corresponding maximum stress amplitude value of the welding seam area of the trailer hanger" step specifically comprises the following steps: according to the SN curve function of the welding seam of the trailer hanger, obtaining the corresponding maximum stress amplitude value of the welding seam area of the trailer hanger under the condition of the preset target durability cycle number and meeting the preset safety constraint condition.
5. A trailer ramp rack endurance simulation analysis optimization system, comprising: comprise: a bench durability test module, configured to obtain the corresponding durability cycle number when the crack appears in the welding seam area of the trailer hanger in the bench durability test; a bench durability simulation analysis module, in communication connection with the bench durability test module, configured to construct a bench durability simulation analysis model and a bench durability simulation analysis condition of the trailer hanger based on the state of the bench durability test of the trailer hanger; call the hyperworks post-processing software to perform simulation analysis, obtain the stress distribution state of the welding seam area of the trailer hanger and the stress amplitude value of the corresponding position of the welding seam area of the trailer hanger when the crack appears in the bench durability test; The SN curve function construction module is in communication connection with the bench durability experiment module and the bench durability simulation analysis module, is configured to construct an SN curve function of the trailer hook weld according to the corresponding durability cycle number and the stress amplitude when the trailer hook weld area has cracks, and is configured to obtain the maximum stress amplitude corresponding to the trailer hook weld area according to the SN curve function of the trailer hook weld. The connection adjustment module is in communication connection with the bench durability simulation analysis module and the SN curve function construction module, is configured to obtain the weld over-standard area of the trailer hook that exceeds the maximum stress amplitude according to the stress distribution state of the trailer hook, and is configured to adjust the connection mode of the trailer hook weld area to bolt connection according to the weld over-standard area. The bench durability simulation analysis module is configured to obtain trailer hook data consistent with the bench durability experiment state of the trailer hook, the trailer hook data including CAD data and material information data; construct a finite element simulation analysis model of the trailer hook according to the CAD data; and perform material attribute assignment on the finite element simulation analysis model of the trailer hook according to the material information data, to obtain a bench durability simulation analysis model of the trailer hook.
6. The trailer rack durability simulation analysis optimization system of claim 5, wherein, The bench durability simulation analysis module is further configured to constrain the freedom of the bolt holes of the mounting plates on both sides of the trailer hook in the bench durability simulation analysis model of the trailer hook, and to apply external loads consistent with the bench durability experiment of the trailer hook at the positions of the trailer hook ball head.
7. The trailer rack durability simulation analysis optimization system of claim 5, wherein, The SN curve function construction module is configured to, The SN curve function of the trailer hook weld is as follows: ； In the formula, N is the durability cycle number; S is the stress amplitude.
8. The trailer rack durability simulation analysis optimization system of claim 5, wherein, The SN curve function construction module is further configured to obtain the maximum stress amplitude corresponding to the trailer hook weld area under the condition of a preset target durability cycle number and satisfying a preset safety constraint condition according to the SN curve function of the trailer hook weld.