A method for manufacturing a steel-aluminum composite vehicle suspension swing arm

Abstract

The application discloses a kind of steel-aluminum composite material vehicle suspension beam manufacturing method, extracts the geometric characteristics of the outer surface of vehicle suspension beam to be made;The entity model of vehicle suspension beam is manufactured, and the entity model of vehicle suspension beam is topologically optimized using solid isotropic material penalty model, and the main load-bearing area in the entity structure of vehicle suspension beam is extracted as the steel framework structure action area;The steel framework structure is manufactured by arc additive manufacturing;Sand mold is manufactured, and the steel framework structure is positioned and placed in the preset position in sand mold, aluminum alloy pouring is started, and after aluminum alloy is completely cooled, sand mold is disassembled to obtain steel-aluminum composite material vehicle suspension beam;The steel framework structure of vehicle suspension beam is manufactured by arc additive manufacturing in the application, and then aluminum alloy pouring is carried out, so as to not only ensure the lightweight performance of aluminum alloy vehicle suspension beam structure, but also improve the strength, stiffness, impact resistance and durability with the aid of steel structure.

Description

Technical Field

[0001] This invention relates to the field of vehicle suspension crossarm manufacturing technology, and in particular to a method for manufacturing a steel-aluminum composite vehicle suspension crossarm. Background Technology

[0002] As a crucial load-bearing component of a vehicle structure, the suspension control arm must withstand longitudinal forces during acceleration and braking, as well as lateral and vertical forces during steering. It is a vital structure ensuring good ride comfort, shock absorption, vehicle stability, handling stability, and reliable transmission of forces and torques between the vehicle body and wheels. Traditionally, vehicle suspension control arms are manufactured using forging, casting, or machining, with materials such as aluminum alloy or steel. Pure steel suspension control arms offer good strength and stiffness, capable of withstanding high loads and vibrations; special steels like stainless steel can also be used to improve corrosion resistance, meeting performance requirements. However, the high density of steel significantly increases the overall structural weight. Therefore, pure aluminum alloys suffer from lower strength, stiffness, impact resistance, and durability, while using pure steel structures results in a significant increase in structural weight. Aluminum alloy suspension control arm structures enable lightweight vehicle design, but offer some performance limitations.

[0003] To address the aforementioned problems, this invention provides a method for manufacturing a steel-aluminum composite vehicle suspension crossarm, thereby solving the challenges of low strength, low stiffness, and low impact resistance in aluminum alloy vehicle suspension crossarms. Summary of the Invention

[0004] The purpose of this invention is to provide a method for manufacturing a steel-aluminum composite vehicle suspension crossarm. The steel frame structure of the vehicle suspension crossarm is manufactured using arc additive manufacturing technology, followed by aluminum alloy casting. This not only ensures the lightweight performance of the aluminum alloy vehicle suspension crossarm structure, but also improves the strength, stiffness, impact resistance, and durability by utilizing the steel structure.

[0005] To achieve the above objectives, the present invention provides the following solution:

[0006] A method for manufacturing a steel-aluminum composite material vehicle suspension control arm includes the following steps:

[0007] Extract the geometric features of the outer surface of the suspension cross arm of the vehicle to be manufactured;

[0008] A solid model of the vehicle suspension cross arm is created. The solid model of the vehicle suspension cross arm is then subjected to topology optimization using a solid isotropic material penalty model. The main load-bearing areas in the solid structure of the vehicle suspension cross arm are extracted and used as the working area of ​​the steel frame structure.

[0009] The steel frame structure is manufactured using electric arc additive manufacturing.

[0010] Based on the physical model of the vehicle suspension cross arm, a sand mold is manufactured. The steel frame structure is positioned in the preset position in the sand mold, and aluminum alloy casting begins. After the aluminum alloy has completely cooled, the sand mold is disassembled to obtain the steel-aluminum composite vehicle suspension cross arm.

[0011] Preferably, the geometric features of the outer surface of the vehicle suspension crossarm include the inner diameter, outer diameter, central axis, and main curved surface of the vehicle suspension crossarm sleeve.

[0012] Preferably, the steel frame structure includes an upper chord, a lower chord, and a web rib structure.

[0013] Preferably, the steel frame structure is manufactured as follows:

[0014] The substrate is manufactured using electric arc additive manufacturing.

[0015] Move the machine tool to the origin, first extract the coordinates of the 90° unsupported rod in the web rib structure, number them from 1 to N in ascending order according to the distance of the coordinates from the origin, move the machine tool to coordinate 1 unsupported rod, and start the deposition of rod 1 on the substrate, and complete the deposition of the Nth 90° unsupported rod in sequence according to the number.

[0016] Manufacture unsupported rods at other angles in the nearby structure using the method described above;

[0017] The upper winding is manufactured according to the above method;

[0018] Based on the geometric model of the lower chord of the steel frame structure, the substrate is wire-cut.

[0019] Preferably, both the substrate and the welding wire are made of austenitic stainless steel.

[0020] Preferably, the diameter of the unsupported rod is set to 4mm to 12mm, and the distance between the upper and lower chords of the steel frame and the upper and lower surfaces of the vehicle suspension crossarm is set to 20mm to 25mm.

[0021] The present invention achieves the following technical effects compared to the prior art:

[0022] 1. This invention manufactures a steel frame structure for a vehicle suspension crossarm using electric arc additive manufacturing technology, followed by aluminum alloy casting. This not only ensures the lightweight performance of the aluminum alloy vehicle suspension crossarm structure, but also improves its strength, stiffness, impact resistance, and durability by utilizing the steel structure. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the structure of the vehicle suspension cross arm of the present invention;

[0025] Figure 2 This is a schematic diagram of the steel frame structure of the present invention;

[0026] Figure 3 This is a flowchart of the manufacturing method of the present invention;

[0027] Among them, 1. Vehicle suspension cross arm; 2. Steel frame structure; 3. Upper chord; 4. Lower chord; 5. Web rib. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] The purpose of this invention is to provide a method for manufacturing a steel-aluminum composite vehicle suspension crossarm. The steel frame structure of the vehicle suspension crossarm is manufactured using arc additive manufacturing technology, followed by aluminum alloy casting. This not only ensures the lightweight performance of the aluminum alloy vehicle suspension crossarm structure, but also improves the strength, stiffness, impact resistance, and durability by utilizing the steel structure.

[0030] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0031] refer to Figures 1 to 3 A method for manufacturing a steel-aluminum composite material vehicle suspension control arm includes the following steps:

[0032] S1. First, extract the geometric features of the outer surface of the vehicle suspension crossarm, including the inner diameter, outer diameter, central axis, and main curved surface of the vehicle suspension crossarm sleeve.

[0033] Topology optimization was performed on the solid model of the vehicle suspension crossarm using a solid isotropic material penalty model to extract the main load-bearing area in the solid structure of the vehicle suspension crossarm, which was then used as the working area of ​​the steel frame structure.

[0034] The steel frame structure is divided into an upper chord, a lower chord, and a web reinforcement structure. The lower chord of the steel frame structure is made of a substrate manufactured by arc additive manufacturing, while the upper chord and web reinforcement are made of support rods manufactured by arc additive manufacturing. In this invention, the diameter of the support rods is set to 8mm to 10mm, and the distance between the upper and lower chords of the steel frame and the upper and lower surfaces of the vehicle suspension crossarm is set to 20mm to 25mm, ensuring that the steel frame structure is embedded within the solid structure and is not exposed.

[0035] The steel skeleton web reinforcement is filled with a lattice structure with high rigidity and high strength.

[0036] S2, Manufacturing of steel frame structure

[0037] The steel frame structure is manufactured using arc additive manufacturing technology; both the substrate and the welding wire are made of austenitic stainless steel, which has good weldability, mechanical properties and corrosion resistance.

[0038] Move the machine tool to the origin. First, extract the coordinates of the 90° unsupported rods in the rib structure, and number them in ascending order according to their distance from the origin. Move the machine tool to coordinate position 1 (unsupported rod) and begin deposition of rod 1. Complete the deposition of the 90° unsupported rods sequentially according to the numbering.

[0039] After the 90° unsupported rod in the rib structure is manufactured, manufacture the unsupported rods at other angles in the nearby structure. Number them in ascending order based on their distance from the origin. Move the machine tool to the coordinate of unsupported rod number 1 and begin the deposition of rod number 1. Complete the deposition of unsupported rods in the rib structure in sequence according to their numbering.

[0040] Finally, the unsupported upper chord members of the steel frame structure are manufactured. They are numbered in ascending order based on their distance from the origin. The machine tool is moved to coordinate position 1 for unsupported member, and deposition of member 1 begins. The deposition of the unsupported upper chord members is completed sequentially according to their numbering.

[0041] This manufacturing method avoids interference between the wire feed tube and the unsupported rod.

[0042] S3. Machining of steel frame

[0043] Based on the CAD geometric model of the lower chord of the steel frame structure, the substrate is wire-cut.

[0044] S4, Aluminum Alloy Casting

[0045] The vehicle suspension control arm is constructed using an aluminum alloy sand casting process. A sand mold is created based on the CAD model of the vehicle suspension control arm for casting. Before casting, the internal steel frame structure of the vehicle suspension control arm is positioned within the sand mold, and aluminum alloy casting begins. After the aluminum alloy has completely cooled, the outer sand mold is removed, and the steel-aluminum composite vehicle suspension control arm is taken out.

[0046] This invention manufactures a steel frame structure for a vehicle suspension crossarm using arc additive manufacturing technology, followed by aluminum alloy casting. This not only ensures the lightweight performance of the aluminum alloy vehicle suspension crossarm structure, but also improves its strength, stiffness, impact resistance, and durability by utilizing the steel structure.

[0047] Any adaptive changes made according to actual needs are within the scope of protection of this invention.

[0048] It should be noted that, for those skilled in the art, it is obvious that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A method for manufacturing a steel-aluminum composite material vehicle suspension cross arm, characterized in that, Includes the following steps: Extract the geometric features of the outer surface of the suspension cross arm of the vehicle to be manufactured; The geometric features of the outer surface of the vehicle suspension arm include the inner diameter, outer diameter, central axis, and main curved surface of the vehicle suspension arm sleeve. A solid model of the vehicle suspension cross arm is created. The solid model of the vehicle suspension cross arm is then subjected to topology optimization using a solid isotropic material penalty model. The main load-bearing areas in the solid structure of the vehicle suspension cross arm are extracted and used as the working area of ​​the steel frame structure. The steel frame structure includes an upper chord, a lower chord, and a web reinforcement structure; The steel frame structure is manufactured using electric arc additive manufacturing. According to the physical model of the vehicle suspension cross arm, a sand mold is manufactured, the steel frame structure is positioned in the preset position in the sand mold, aluminum alloy casting begins, and after the aluminum alloy has completely cooled, the sand mold is disassembled to obtain the steel-aluminum composite vehicle suspension cross arm. The method for manufacturing the steel frame structure is as follows: The substrate is manufactured using electric arc additive manufacturing. Move the machine tool to the origin, first extract the coordinates of the 90° unsupported rod in the web rib structure, number them from 1 to N in ascending order according to the distance of the coordinates from the origin, move the machine tool to the coordinate of the 1st unsupported rod, and start the deposition of the 1st rod on the substrate, and complete the deposition of the Nth 90° unsupported rod in sequence according to the number. Manufacture unsupported rods at other angles in the nearby structure using the method described above; The upper winding is manufactured according to the above method; Based on the geometric model of the lower chord of the steel frame structure, the substrate is wire-cut.

2. The method for manufacturing a steel-aluminum composite vehicle suspension cross arm according to claim 1, characterized in that, Both the substrate and the welding wire are made of austenitic stainless steel.

3. The method for manufacturing a steel-aluminum composite vehicle suspension cross arm according to claim 1, characterized in that, The diameter of the unsupported rod is set to 4mm to 12mm, and the distance between the upper and lower chords of the steel frame and the upper and lower surfaces of the vehicle suspension crossarm is set to 20mm to 25mm.

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