Lightweight design method, system, equipment and medium of two-force lever control arm

Abstract

The application relates to the technical field of vehicle manufacturing, in particular to a lightweight design method, system, equipment and medium of a two-force rod type control arm. The method provided by the application firstly determines the stiffness target of the control arm and the initial topology space according to the vehicle parameters before the topology optimization stage, and verifies the stiffness of the topology space, performs topology optimization with the stiffness as a constraint condition and volume minimization as a target in the topology optimization stage, simultaneously, the minimum member size and the non-hole constraint are additionally set, the stiffness and strength performance of the control arm is rechecked after the fairing and engineering treatment of the control arm, in the case that the stiffness and strength performance meets the preset requirement, the process analysis of the control arm structure is performed, the process feasibility of the control arm structure is evaluated, the blind optimization caused by the insufficient topology space is effectively avoided, and multiple structure modifications and rechecks are avoided, the lightweight of the control arm structure is realized, and the control arm structure also has the structural reliability and the manufacturability.

Description

Technical Field

[0001] This application relates to the field of vehicle manufacturing technology, specifically to a lightweight design method, system, device, and medium for a two-force bar control arm. Background Technology

[0002] As a structure that bears the force in the direction of the two-force bar axis of the vehicle chassis suspension system, the two-force bar control arm has strict stiffness requirements, and its performance directly affects the vehicle's comfort and handling.

[0003] When designing two-force bar control arms, topology optimization is often used. However, in related design methods, the topology optimization results are often disconnected from the stiffness target. This leads to repeated topology iterations. Some methods ignore the initial spatial constraints, which can easily lead to blind optimization and iteration failures. At the same time, the topology optimization results contain many fragmented structures and holes, making the structure complex and difficult to manufacture. In addition, conventional design processes usually evaluate the manufacturing process only after the structure is finalized, which leads to problems such as rework and increased design time costs. Summary of the Invention

[0004] This application aims to address at least one of the technical problems existing in the prior art. To this end, this application proposes a lightweight design method, system, device, and medium for a two-force bar control arm. By using stiffness as a direct constraint for hole-free topology optimization, a two-force bar control arm design that can be implemented and meets various requirements is realized, effectively avoiding blind optimization and repeated iterations.

[0005] In a first aspect, embodiments of this application provide a lightweight design method for a two-force bar control arm, comprising: determining the stiffness target of the control arm in the two-force bar direction based on vehicle parameters; determining the initial topology space of the control arm and performing stiffness analysis on the initial topology space to verify whether the stiffness of the initial topology space meets the stiffness target; in response to the stiffness of the initial topology space meeting the stiffness target, performing topology optimization on the initial topology space with the stiffness target as a constraint and minimizing the volume of the control arm as the optimization objective to generate a preliminary structure of the control arm, wherein the topology optimization process includes at least setting minimum member size constraints and setting no-hole constraints; performing smoothing and engineering processing on the preliminary structure of the control arm to determine the target control arm structure; performing stiffness and strength simulation analysis on the target control arm structure to verify the stiffness and strength performance of the target control arm structure; and in response to the stiffness and strength performance meeting preset requirements, performing process simulation analysis on the target control arm structure to evaluate the process feasibility of the target control arm structure and predict manufacturing defects.

[0006] In some embodiments, determining the initial topological space of the control arm includes: extracting the motion envelope of the peripheral components of the control arm using kinematic simulation software; after removing the motion envelope and reserved gaps from the vehicle assembly space, connecting the hard points on both sides of the control arm and the space near the hard points to form the initial topological space, wherein the hard point is the theoretical connection point of the control arm in the vehicle suspension system, located at the center of the bushings at both ends of the control arm, and is used to determine the arrangement orientation of the control arm and the direction of the two force members.

[0007] In some embodiments, stiffness analysis of the initial topological space includes: dividing the initial topological space into a three-dimensional solid mesh, and establishing rigid elements with the hard points on both sides as master points and the nodes adjacent to the hard points in the three-dimensional solid mesh as slave points; applying constraints at one side of the hard point and applying a predetermined load along the two-force member direction at the other side of the hard point; solving for the displacement of the other side of the hard point in the two-force member direction; and determining that the stiffness of the initial topological space satisfies the stiffness target in response to the displacement being less than or equal to the ratio of the predetermined load to the stiffness target.

[0008] In some embodiments, the topology optimization process includes at least setting a draft direction or parting surface to limit the forming direction of the topology optimization result.

[0009] In some embodiments, the engineering process includes adjusting the dimensions of the target control arm structure and increasing the machined surfaces.

[0010] In some embodiments, the process simulation analysis includes casting process simulation analysis; performing process simulation analysis on the target control arm structure includes: specifying the target control arm structure as a casting part, selecting the process type and material of the target control arm structure, setting the pouring temperature, mold preheating temperature and gravity direction; establishing a gating system and generating a mold; setting process parameters, dividing the mesh, and running the simulated filling and solidification process of the target control arm structure; analyzing the results of the simulated filling and solidification process to identify defects such as shrinkage porosity, shrinkage cavity, air entrapment and cold shut.

[0011] In some embodiments, the process simulation analysis includes forging process simulation analysis; process simulation analysis of the target control arm structure includes: establishing a pre-forging die, a final forging die, and a billet model based on the target control arm structure; selecting the process type, forging type, and solver of the target control arm structure; setting the forging material and die temperature of the target control arm structure; setting the press type, friction and heat exchange parameters, meshing, and setting the time step and termination conditions; and checking the filling rate, flow vector, and equivalent strain to identify defects such as incomplete filling, folding, and cracks.

[0012] Secondly, embodiments of this application provide a lightweight design system for a two-force bar control arm, comprising: a determination module configured to determine a stiffness target of the control arm in the two-force bar direction based on vehicle parameters; a verification module configured to determine an initial topology space of the control arm and perform stiffness analysis on the initial topology space to verify whether the stiffness of the initial topology space meets the stiffness target; and a response module configured to, in response to the stiffness of the initial topology space meeting the stiffness target, perform topology optimization on the initial topology space with the stiffness target as a constraint and minimizing the volume of the control arm as the optimization objective, generate... The system includes a preliminary structure for the control arm, where topology optimization includes setting minimum member size constraints and no-hole constraints; a processing module configured to smooth and engineer the preliminary structure of the control arm to determine the target control arm structure; a verification module configured to perform stiffness and strength simulation analysis on the target control arm structure to verify its stiffness and strength performance; and an analysis module configured to perform process simulation analysis on the target control arm structure in response to the stiffness and strength performance meeting preset requirements, to evaluate the process feasibility of the target control arm structure and predict manufacturing defects.

[0013] Thirdly, embodiments of this application provide an electronic device, including: a processor and a memory, wherein the memory stores a program or instructions that can run on the processor, and when the program or instructions are executed by the processor, the steps of the lightweight design method of the two-force lever control arm as described in the first aspect are implemented.

[0014] Fourthly, embodiments of this application provide a computer-readable storage medium storing a program or instructions that, when executed by a processor, implement the steps of the lightweight design method for the two-lever control arm as described in the first aspect.

[0015] The technical solution provided in this application first determines the stiffness target and initial topology space of the control arm based on vehicle parameters before the topology optimization stage, and verifies the stiffness of the topology space. Then, in the topology optimization stage, stiffness is directly used as a constraint condition, and topology optimization is performed with volume minimization as the objective. Simultaneously, minimum member size and no-pore constraints are set to ensure that the optimized preliminary structure achieves both lightweighting and stiffness targets in one go, eliminating the difficult-to-manufacture porous features from the source. The control arm is further smoothed and engineered to determine its structure. Stiffness and strength analysis is performed on the control arm structure to verify its stiffness and strength performance. If the stiffness and strength performance meets the preset requirements, process analysis is conducted on the control arm structure to evaluate its manufacturability. The solution provided in this application effectively avoids blind optimization caused by insufficient topology space and avoids multiple structural modifications and verifications, achieving lightweight control arm structure while maintaining structural reliability and manufacturability.

[0016] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0017] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 A flowchart illustrating a lightweight design method for a two-force bar control arm provided in an embodiment of this application; Figure 2 A flowchart for performing stiffness analysis on the initial topological space provided in this application embodiment; Figure 3 A schematic diagram of the stiffness analysis model for the initial topological space provided in this application; Figure 4 This is a schematic diagram of space division provided for an embodiment of this application; Figure 5 A first-view schematic diagram of the control arm topology optimization analysis results provided in an embodiment of this application; Figure 6 A second-view schematic diagram of the control arm topology optimization analysis results provided in an embodiment of this application; Figure 7 A first-view schematic diagram of the smoothed control arm provided in an embodiment of this application; Figure 8 A second-view schematic diagram of the smoothed control arm provided in an embodiment of this application; Figure 9 A first-view schematic diagram of the target control arm structure provided in the embodiments of this application; Figure 10 This is a second-view schematic diagram of the target control arm structure provided in an embodiment of this application; Figure 11 A flowchart for simulation analysis of casting forming process provided in the embodiments of this application; Figure 12 A flowchart for simulation analysis of the forging process provided in the embodiments of this application; Figure 13 A schematic diagram of a lightweight design system for a two-force bar control arm provided in an embodiment of this application; Figure 14 This is a schematic diagram of a more specific electronic device hardware structure provided for an embodiment of this application.

[0018] Reference numerals: 1300 - Lightweight design system for two-force lever control arm; 1310 - Determining module; 1320 - Verification module; 1330 - Response module; 1340 - Processing module; 1350 - Verification module; 1360 - Analysis module; 1410 - Processor; 1420 - Memory; 1430 - Input / output interface; 1440 - Communication interface; 1450 - Bus. Detailed Implementation

[0019] Embodiments of this application will now be described in more detail with reference to the accompanying drawings. While some embodiments of this application are shown in the drawings, it should be understood that this application can be implemented in various forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of this application. It should be understood that the drawings and embodiments of this application are for illustrative purposes only and are not intended to limit the scope of protection of this application.

[0020] It should be understood that the steps described in the method embodiments of this application may be performed in different orders and / or in parallel. Furthermore, the method embodiments may include additional steps and / or omit the steps shown. The scope of this application is not limited in this respect.

[0021] refer to Figure 1 The flowchart shows a lightweight design method for a two-force bar control arm provided in the embodiments of this application.

[0022] Step S101: Determine the stiffness target of the control arm in the two-force member direction based on the vehicle parameters.

[0023] Specifically, the structure of the suspension system is determined based on the vehicle model. Before designing the control arm structure, it is necessary to first determine the corresponding vehicle parameters for the vehicle model. These parameters include the vehicle type (e.g., sedan or SUV), the vehicle's axle load parameters, and the vehicle's suspension type (e.g., trapezoidal arm multi-link or five-link). Based on the vehicle parameters, the stiffness target of the control arm in the direction of the two-force bar axis is determined, which is used as the stiffness constraint condition for subsequent topology optimization.

[0024] Step S102: Determine the initial topology space of the control arm and perform stiffness analysis on the initial topology space to verify whether the stiffness of the initial topology space meets the stiffness target.

[0025] Specifically, after obtaining the vehicle parameters and determining the stiffness target of the control arm in the two-force bar direction, in order to obtain the basic design region available for topology optimization, it is necessary to determine the initial topology space of the control arm. The topology space is used to represent the maximum design region that can enclose all possible material distributions under the premise of satisfying the vehicle's non-performance constraints. It is usually represented in the form of a three-dimensional solid envelope model. Further stiffness analysis is performed on the initial topology space to verify whether the initial topology space can meet the stiffness target determined above.

[0026] As an optional embodiment, determining the initial topological space of the control arm includes: extracting the motion envelope of the peripheral components of the control arm using kinematic simulation software; after removing the motion envelope and reserved gaps from the vehicle assembly space, connecting the hard points on both sides of the control arm and the space near the hard points to form the initial topological space, wherein the hard point is the theoretical connection point of the control arm in the vehicle suspension system, located at the center of the bushings at both ends of the control arm, and is used to determine the arrangement orientation of the control arm and the direction of the two force members.

[0027] Specifically, when determining the initial topology space of the control arm, the motion envelope of the surrounding components of the control arm needs to be extracted first using kinematic simulation software. This kinematic simulation software includes, but is not limited to, ADAMS / Car or CATIA DMU software. The kinematic simulation software can extract the three-dimensional envelope space of the surrounding components of the control arm under all possible motion trajectories, taking into account typical operating conditions such as the maximum vertical travel, maximum steering angle, and longitudinal tilt under braking or acceleration conditions when the vehicle is fully loaded or unloaded. Further, the motion envelope space and the required reserved clearance are removed from the vehicle assembly space, and the space of the hard points on both sides of the control arm and the area near the hard points is connected to form the initial topology space. It should be noted that in the simulation modeling of the vehicle suspension system, to facilitate computer processing, the bushing center, which has practical significance, is usually abstracted into a theoretical three-dimensional geometric coordinate point, i.e., the aforementioned hard point. Based on the spatial position of the hard point, the arrangement orientation of the control arm and the direction of the two-force members can be determined, realizing the accurate mechanical positioning of the axial force direction that needs to be followed during topology optimization, providing a rigorous theoretical basis for subsequent stiffness analysis.

[0028] refer to Figure 2 This is a flowchart of stiffness analysis of the initial topological space provided in an embodiment of this application.

[0029] Step S201: Divide the initial topological space into a three-dimensional solid mesh, and establish rigid elements with the hard points on both sides as the main points and the nodes at the adjacent hard points in the three-dimensional solid mesh as the slave points.

[0030] Specifically, after determining the initial topology space of the control arm, a stiffness analysis is further performed on the initial topology space to verify whether it meets the stiffness target of the control arm. Specifically, the initial topology space is first divided into three-dimensional solid network elements. The hard points on both sides of the control arm are taken as master points, and the outer surface nodes of the bushing adjacent to each hard point are taken as slave points to establish rigid elements (i.e., rb2 elements). The type of the three-dimensional solid network element is preferably a second-order tetrahedron. By establishing rigid elements, the force transmission relationship between the bushing and the control arm body during actual operation can be simulated, thereby avoiding stress concentration when the load is applied. After completing the network element division, the required material parameters are defined, including but not limited to density, elastic modulus and Poisson's ratio, etc. At the same time, the properties of the three-dimensional solid elements are set and assigned to the corresponding three-dimensional solid network elements.

[0031] refer to Figure 3 This is a schematic diagram of the stiffness analysis model for the initial topological space provided in this application.

[0032] Step S202: Apply a constraint at one hard point and apply a predetermined load along the direction of the two-force member at the other hard point.

[0033] Specifically, to establish accurate analysis coordinates, a local coordinate system is established with the hard point on one side of the control arm as the origin, the direction connecting the hard point on the other side of the origin as the X-axis, the axial direction of the sleeve at the origin as the Z-axis, and the direction perpendicular to both the X-axis and Z-axis as the Y-axis. The origin of the local coordinate system is set as hard point A, and the hard point on the other side of the control arm is set as hard point B. Furthermore, the degrees of freedom in directions 1 to 4 are constrained at hard point A, and the degrees of freedom in directions 2 to 3 are constrained at hard point B. At the same time, a predetermined load is applied at hard point B along the direction of the two-force member. In this embodiment, the predetermined load is preferably 1000N.

[0034] Step S203: Solve to obtain the displacement of the hard point on the other side in the direction of the two-force member; Step S204: In response to the displacement being less than or equal to the ratio of the predetermined load to the stiffness target, determine that the stiffness of the initial topological space satisfies the stiffness target.

[0035] Specifically, further, stiffness analysis is performed by obtaining the displacement of hard point B in the direction of the two-force member in the local coordinate system, where the displacement represents the deformation of the control arm under a given load, denoted as . Further verification and judgment of the displacement: if the displacement If the ratio of the predetermined load to the target stiffness of the control arm is less than or equal to the ratio of the load to the target stiffness of the control arm, then the current initial topology space can be determined to meet the target stiffness of the control arm, and subsequent topology optimization analysis can continue; if the displacement... If the ratio of the predetermined load to the target stiffness of the control arm is greater than the ratio of the predetermined load to the target stiffness of the control arm, it means that the current initial topology space does not meet the target stiffness of the control arm. In this case, it is necessary to adjust the arrangement of other components around the control arm, increase the topology space for the control arm, and re-analyze until the target stiffness of the control arm is met. It should be noted that the ratio of the predetermined load to the target stiffness of the control arm is the theoretically allowed maximum displacement.

[0036] refer to Figure 4 This is a schematic diagram of space division provided in an embodiment of this application.

[0037] Step S103: In response to the stiffness of the initial topology space satisfying the stiffness target, the initial topology space is optimized with the stiffness target as a constraint and the volume of the control arm as the optimization objective, to generate the preliminary structure of the control arm. The topology optimization process includes at least setting minimum member size constraints and setting no-hole constraints.

[0038] Specifically, under the condition that the initial topological space meets the stiffness target of the control arm, topological optimization is performed on the initial topological space, including: spatial partitioning of the initial topological space into non-design space and design space. The connection area between the control arm and the bushing and its surrounding area can be set as non-design space, and other areas can be set as design space. This ensures that the optimization algorithm can be applied to the excess material of the control arm without compromising the assembly function or introducing stress concentration, thereby obtaining a control arm structure that can meet the stiffness target, reduce weight, and be directly used for engineering design. Further, the design space and non-design space are respectively divided into first-order tetrahedral three-dimensional solid network elements, and the nodes at the boundary between the design space and non-design space are shared. Rigid elements are established according to steps S201 and S202, and the loading steps for stiffness analysis are set according to the same constraints and loads. The minimum member size of the design space and the no-hole constraint are set. The minimum member size is preferably three times or more of the average network size, and no maximum member size is set.

[0039] As an optional embodiment, the topology optimization process includes at least setting a draft direction or parting surface to limit the forming direction of the topology optimization result.

[0040] Specifically, to ensure that the solid manufacturing process is considered during the design of the control arm structure, i.e., to ensure that the parts can be smoothly ejected from the mold after forming, this application can combine the absence of holes in the topology optimization process. In the kinematic simulation software, a unidirectional or bidirectional draft direction can be pre-specified, or a specific parting surface can be defined. By setting the draft direction or parting surface, the topology optimization algorithm can strictly follow the set forming direction when iteratively peeling off the material in the low strain energy region. This ensures that there is no obstruction on the projection surface of the set ejection direction, and that the generated preliminary structure of the control arm can meet the requirements of stiffness and lightweight, while also having strong casting or forging demoldability. This avoids the risk of being forced to modify the shape and re-optimize due to the inability to process the parts in traditional optimization.

[0041] refer to Figures 5-6 The diagram shows the first and second perspectives of the control arm topology optimization analysis results provided in the embodiments of this application.

[0042] After setting the minimum member size of the design space, the absence of hole constraints, and the draft direction or parting surface, the topology optimization process is executed: the response under the topology optimization process is established, that is, the displacement of hard point B in the direction of the two-force member in the local coordinate system. and the overall volume of the control arm , displacement Set the constraints for the topology optimization process, and set the total volume The objective is set as the topology optimization objective. After establishing the above-mentioned response, constraints, and objective, topology optimization analysis and calculation are performed to obtain the optimization results. In this application, it is preferable to set the isosurface threshold of the optimization results to 0.3, and further derive the following... Figure 5 The .fem format mesh file shown is the optimized result; the exported file is the preliminary structure of the required control arm.

[0043] refer to Figures 7-8 The diagram shows the first and second perspective views of the smoothed control arm provided in the embodiments of this application.

[0044] Step S104: Smooth and engineer the preliminary structure of the control arm to determine the target control arm structure.

[0045] Specifically, the preliminary structural file of the control arm exported above is imported into structural simulation and design optimization engineering software for smoothing. The preferred software for this purpose is Altair Inspire. The smoothed file is then exported as a .stp geometry file. Further, the exported .stp geometry file is imported into 3D modeling software (such as Catia), and some structural dimensions are adjusted based on the optimization results. Engineering processing is then performed, and the resulting engineered file represents the target control arm structure. Figures 9-10As shown, where Figure 9 This is a first-person view diagram of the target control arm structure. Figure 10 The second perspective view of the target control arm structure.

[0046] As an optional embodiment, the engineering process includes adjusting the dimensions of the target control arm structure and increasing the machined surfaces.

[0047] Specifically, since the smoothed geometric model is mainly generated based on the optimal force transmission path calculated by the topology optimization algorithm, its local dimensions may not be directly compatible with existing standard parts. Therefore, it is necessary to adjust the dimensions of the control arm structure in the 3D modeling software. This involves matching and correcting the characteristic dimensions such as the inner and outer diameters and lengths of the sleeves (i.e., bushing mounting holes) at both ends of the control arm with the pre-selected standard bushing dimensions. In addition, to avoid stress concentration in the control arm after forming, it is also necessary to make standardized fine adjustments or supplements to the transition areas, wall thickness, and rounded corners of the local cross-sections of the control arm body to ensure the continuity and smoothness of the structure. In terms of machining, since the control arm is usually formed by casting or forging, the surface roughness and dimensional accuracy of the cast or forged blank cannot directly meet the high-precision assembly requirements of the chassis suspension system. Therefore, it is necessary to reserve machining allowance in the contact area where the control arm blank directly mates with the surrounding parts. This involves adding a solid layer to the 3D model to form a machining surface, so that the allowance can be removed through subsequent machining after the actual control arm blank is formed, thereby achieving the form and position tolerances required by the control arm design.

[0048] Step S105: Perform stiffness and strength simulation analysis on the target control arm structure to verify the stiffness and strength performance of the target control arm structure.

[0049] Specifically, stiffness and strength simulation analysis is performed on the target control arm structure obtained above. Specifically, the three-dimensional geometric model of the target control arm structure can be imported into finite element preprocessing software for re-meshing. Discretization is performed using second-order tetrahedral or hexahedral solid elements, and local mesh refinement is applied to potentially high-stress risk areas (such as bushing transition areas, geometric abrupt changes, and near chamfered edges of added machined surfaces) to ensure the convergence of the calculation results. Furthermore, boundary conditions are set for the model, or various extreme conditions are set. These extreme conditions include, but are not limited to, emergency braking, maximum lateral acceleration cornering, or other chassis-related conditions. The system utilizes various operating conditions to perform stiffness and strength simulation analyses based on the aforementioned settings. Stiffness simulation analysis involves extracting the displacement and deformation along the axis of the two-force member and other key force directions under these conditions, and determining whether these displacements are strictly less than a preset deformation threshold to ensure that the kinematic hard points of the suspension do not excessively shift under load. Strength analysis involves extracting the equivalent stress distribution cloud map from the target control arm structure, checking whether the maximum stress peak value across the entire region is not higher than the yield strength of the selected material, and assessing whether the maximum stress peak value meets the lower limit of the safety factor specified for the entire vehicle. If both stiffness and strength simulation analyses meet the preset requirements, then the target stiffness and strength performance is confirmed to meet the preset requirements.

[0050] Step S106: In response to the fact that the rigidity and strength performance meets the preset requirements, process simulation analysis is performed on the target control arm structure to evaluate the process feasibility of the target control arm structure and predict manufacturing defects.

[0051] Specifically, after confirming that the rigidity and strength performance of the target control arm meets the preset requirements, it is also necessary to conduct process simulation analysis on the target control arm structure. Different process simulation analyses are performed on the control arms formed by casting and forging to accurately assess the process feasibility of the target control arm structure and predict manufacturing defects. Based on the results of the process simulation analysis, the process parameters can be further fine-tuned before actual manufacturing, so as to achieve a refined balance between ensuring the lightweight control arm and meeting performance standards and manufacturability.

[0052] refer to Figure 11 This is a flowchart of the simulation analysis of the casting forming process provided in the embodiments of this application.

[0053] Step S1101: Specify the target control arm structure as a cast part, select the process type and material of the target control arm structure, and set the pouring temperature, mold preheating temperature and gravity direction; Step S1102: Establish the gating system and generate the mold; Step S1103: Set process parameters, divide the mesh, and run the simulated filling and solidification process of the target control arm structure; Step S1104: Analyze the results of the simulated filling and solidification process to identify defects such as shrinkage porosity, shrinkage cavities, air entrapment, and cold shuts.

[0054] Specifically, the target control arm structure is imported into casting process simulation software (such as Inspire Cast), designated as a casting part, and a specific casting process is selected based on the actual production plan, such as high-pressure die casting, low-pressure casting, or gravity mold casting. Simultaneously, the corresponding material properties of the casting need to be selected. The casting process simulation software automatically calls the thermophysical parameters of this material during the liquid and solidification processes. Furthermore, initial boundary conditions are set based on process experience, including the initial pouring temperature of the molten metal, the preheating temperature of the metal mold, and the direction of gravitational acceleration. When establishing the gating system, a complete flow channel network needs to be constructed around the target control arm structure within the simulation software. After completing the gating system modeling, the casting process simulation software can automatically or semi-automatically generate a ring around the casting and the overall gating system. The mold cavity is constructed. Based on the established mold, dynamic process parameters need to be further set. For example, in the die casting process, the multi-stage injection speed of the injection punch, the pressure boosting, the holding time, and the heat transfer coefficient between the mold and the casting interface need to be set. Furthermore, the casting, gating system, and mold are meshed in three dimensions using finite element methods and submitted to the solver to fully simulate the filling and flow process of high-temperature molten metal in the mold cavity and the cooling, solidification, and crystallization process. By analyzing the results of the simulated filling and solidification process, defects such as shrinkage porosity, shrinkage cavities, air entrapment, and cold shuts can be identified. When obvious defects are found, the construction of the gating system or the process parameters can be adjusted to eliminate the defects until a feasible casting process scheme without obvious defects is obtained.

[0055] refer to Figure 12 This is a flowchart of the forging process simulation analysis provided in the embodiments of this application.

[0056] Step S1201: Establish pre-forging die, final forging die, and billet model based on the target control arm structure; Step S1202: Select the process type, forging type and solver of the target control arm structure, and set the forging material and mold temperature of the target control arm structure; Step S1203: Set the press type, friction and heat exchange parameters, generate a mesh, and set the time step and termination conditions; Step S1204: Check the filling rate, flow vector and equivalent strain to identify defects such as incomplete filling, folds and cracks.

[0057] Specifically, the target control arm structure is imported into 3D modeling software. In the 3D modeling software, a pre-forging die for the target control arm is constructed by extending its length, increasing machining allowance, considering thermal shrinkage, and setting forging draft angles. Based on the pre-forging die, flash grooves are further designed and a final forging die is generated. Simultaneously, to ensure uniform flow of the metal material within the die, an initial blank (bulk) model needs to be built in reverse. The aforementioned pre-forging die, final forging die, and blank model are imported into professional forging process simulation software (e.g., Simufact.Forming). The process type, forging type, and solver of the target control arm structure are selected. In this embodiment, the current process type is preferably die forging, the forging type is hot forging, the simulation type is 3D, and the finite volume method (FV) is preferred as the solver. The target control arm structure is then called. The forging material corresponding to the control arm structure is used to obtain its rheological stress curve and thermophysical parameters. In order to simulate the real production environment, the mold preheating temperature is also set. Furthermore, the press type (such as hydraulic press or mechanical press) is set to determine the accurate pressing stroke curve. It is also necessary to set the friction parameters between the billet and the mold surface and the heat exchange parameters. Under the condition of setting the above parameters, the billet is meshed, and the calculation time step and termination condition are set. The above configuration is submitted to the solver for calculation. After the simulation calculation is completed, by checking the filling rate, flow vector and equivalent strain of the metal material, defects such as incomplete filling, folds and cracks can be detected. When obvious defects are found, the process parameters can be optimized or the mold or target control arm structure can be fine-tuned to eliminate defects until a feasible casting process scheme without obvious defects is obtained.

[0058] According to the lightweight design method of the two-force bar control arm provided in this application, before the topology optimization stage, the stiffness target and initial topology space of the control arm are first determined based on vehicle parameters, and the stiffness of the topology space is verified. Further, in the topology optimization stage, stiffness is directly used as a constraint condition, and topology optimization is performed with volume minimization as the objective. Simultaneously, minimum member size and no-pore constraints are set to ensure that the optimized preliminary structure achieves both lightweight and stiffness targets in one go, eliminating the difficult-to-manufacture porous features from the source. The control arm is then further smoothed and engineered to determine its structure. Stiffness and strength analysis is performed on the control arm structure to verify its stiffness and strength performance. If the stiffness and strength performance meets the preset requirements, process analysis is conducted on the control arm structure to evaluate its process feasibility. The solution provided in this application effectively avoids blind optimization caused by insufficient topology space and avoids multiple structural modifications and verifications, achieving lightweight control arm structure while maintaining structural reliability and manufacturability.

[0059] refer to Figure 13This is a schematic diagram of a lightweight design system for a two-force bar control arm provided in an embodiment of this application.

[0060] Based on the same concept, corresponding to the lightweight design method of the two-force lever control arm provided in the above embodiments, this application also provides a lightweight design system 1300 for a two-force lever control arm, including a determination module 1310, a verification module 1320, a response module 1330, a processing module 1340, a verification module 1350, and an analysis module 1360.

[0061] The determination module 1310 is configured to determine the stiffness target of the control arm in the two-force member direction based on vehicle parameters; the verification module 1320 is configured to determine the initial topology space of the control arm and perform stiffness analysis on the initial topology space to verify whether the stiffness of the initial topology space meets the stiffness target; the response module 1330 is configured to, in response to the stiffness of the initial topology space meeting the stiffness target, perform topology optimization on the initial topology space with the stiffness target as a constraint and minimizing the volume of the control arm as the optimization objective, to generate the preliminary structure of the control arm, wherein the topology optimization... The process includes at least setting minimum member size constraints and setting no-hole constraints; the processing module 1340 is configured to perform smoothing and engineering processing on the preliminary structure of the control arm to determine the target control arm structure; the verification module 1350 is configured to perform stiffness and strength simulation analysis on the target control arm structure to verify the stiffness and strength performance of the target control arm structure; the analysis module 1360 is configured to perform process simulation analysis on the target control arm structure in response to the stiffness and strength performance meeting the preset requirements to evaluate the process feasibility of the target control arm structure and predict manufacturing defects.

[0062] In some embodiments, the verification module 1320 is further configured to: extract the motion envelope of the control arm peripheral components using kinematic simulation software; after removing the motion envelope and reserved gap from the vehicle assembly space, connect the hard points on both sides of the control arm and the space near the hard points to form an initial topological space, wherein the hard point is the theoretical connection point of the control arm in the vehicle suspension system, located at the center of the bushings at both ends of the control arm, and is used to determine the arrangement orientation of the control arm and the direction of the two force members.

[0063] In some embodiments, the verification module 1320 is further configured to: divide the initial topological space into a three-dimensional solid mesh, and establish rigid elements with the hard points on both sides as master points and the nodes at the adjacent hard points in the three-dimensional solid mesh as slave points; apply constraints at one hard point and apply a predetermined load along the two-force member direction at the other hard point; solve for the displacement of the other hard point in the two-force member direction; and determine that the stiffness of the initial topological space satisfies the stiffness target in response to the displacement being less than or equal to the ratio of the predetermined load to the stiffness target.

[0064] In some embodiments, the response module 1330 is further configured to include at least setting a draft direction or parting surface during the topology optimization process to limit the forming direction of the topology optimization result.

[0065] In some embodiments, the processing module 1340 is further configured to: engineering processes include adjusting the dimensions of the target control arm structure and increasing the machining surfaces.

[0066] In some embodiments, the process simulation analysis includes casting process simulation analysis; the analysis module 1360 is further configured to: specify the target control arm structure as a casting part, select the process type and material of the target control arm structure, set the pouring temperature, mold preheating temperature and gravity direction; establish a gating system and generate a mold; set process parameters, divide the mesh, run the simulated filling and solidification process of the target control arm structure; and analyze the results of the simulated filling and solidification process to identify defects such as shrinkage porosity, shrinkage cavity, air entrapment and cold shut.

[0067] In some embodiments, the process simulation analysis includes forging forming process simulation analysis; the analysis module 1360 is further configured to: perform process simulation analysis on the target control arm structure, including: establishing a pre-forging die, a final forging die, and a billet model based on the target control arm structure; selecting the process type, forging type, and solver of the target control arm structure; setting the forging material and die temperature of the target control arm structure; setting the press type, friction and heat exchange parameters, dividing the mesh, setting the time step and termination conditions; and checking the filling rate, flow vector, and equivalent strain to identify incomplete filling, folding, and crack defects.

[0068] The lightweight design system for the two-force lever control arm in the above embodiments is used to implement the lightweight design method for the corresponding two-force lever control arm in any of the foregoing embodiments, and has the beneficial effects of the corresponding lightweight design method for the two-force lever control arm, which will not be elaborated here.

[0069] Based on the same concept, corresponding to the lightweight design method of the two-lever control arm provided in any of the above embodiments, this application also provides an electronic device, including a processor and a memory, wherein the memory stores a program or instruction that can run on the processor, and when the program or instruction is executed by the processor, the lightweight design method of the two-lever control arm described above is implemented.

[0070] Figure 14 This illustration shows a more specific hardware structure diagram of an electronic device according to an embodiment of this application. The device may include: a processor 1410, a memory 1420, an input / output interface 1430, a communication interface 1440, and a bus 1450. The processor 1410, memory 1420, input / output interface 1430, and communication interface 1440 are interconnected internally via the bus 1450.

[0071] The processor 1410 can be implemented using a general-purpose CPU (Central Processing Unit), microprocessor, application-specific integrated circuit (ASIC), or one or more integrated circuits, and is used to execute relevant programs to implement the technical solutions provided in the embodiments of this specification.

[0072] The memory 1420 can be implemented in the form of ROM (Read Only Memory), RAM (Random Access Memory), static storage device, dynamic storage device, etc. The memory 1420 can store the operating system and other applications. When the technical solutions provided in the embodiments of this specification are implemented by software or firmware, the relevant program code is stored in the memory 1420 and is called and executed by the processor 1410.

[0073] The input / output interface 1430 is used to connect input / output modules to realize information input and output. The input / output modules can be configured as components in the device (not shown in the figure) or externally connected to the device to provide corresponding functions. Input devices may include keyboards, mice, touch screens, microphones, various sensors, etc., and output devices may include displays, speakers, vibrators, indicator lights, etc.

[0074] The communication interface 1440 is used to connect a communication module (not shown in the figure) to enable communication between this device and other devices. The communication module can communicate via wired means (such as USB, Ethernet cable, etc.) or wireless means (such as mobile network, WIFI, Bluetooth, etc.).

[0075] Bus 1450 includes a pathway for transmitting information between various components of the device, such as processor 1410, memory 1420, input / output interface 1430, and communication interface 1440.

[0076] It should be noted that although the above-described device only shows the processor 1410, memory 1420, input / output interface 1430, communication interface 1440, and bus 1450, in specific implementations, the device may also include other components necessary for normal operation. Furthermore, those skilled in the art will understand that the above-described device may only include the components necessary for implementing the embodiments of this specification, and not necessarily all the components shown in the figures.

[0077] The electronic devices described above are used to implement the lightweight design method of the corresponding two-force lever control arm in any of the foregoing embodiments, and have the beneficial effects of the corresponding lightweight design method embodiments of the two-force lever control arm, which will not be repeated here.

[0078] Based on the same concept, corresponding to the lightweight design method of the two-lever control arm provided in any of the above embodiments, this application also provides a computer-readable storage medium, on which a program or instruction is stored, and when the program or instruction is executed by a processor, the steps of the lightweight design method of the two-lever control arm are implemented.

[0079] The aforementioned computer-readable storage medium can be any available medium or data storage device that a computer can access, including but not limited to magnetic storage (e.g., floppy disks, hard disks, magnetic tapes, magneto-optical disks (MOs), etc.), optical storage (e.g., CDs, DVDs, BDs, HVDs, etc.), and semiconductor storage (e.g., ROMs, EPROMs, EEPROMs, non-volatile memory (NAND flash), solid-state drives (SSDs)).

[0080] The computer instructions stored in the storage medium of the above embodiments are used to cause the computer to execute the lightweight design method of the corresponding two-force bar control arm in any of the foregoing embodiments, and have the beneficial effects of the corresponding lightweight design method embodiment of the two-force bar control arm, which will not be repeated here.

[0081] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element. Furthermore, it should be noted that the scope of the methods and apparatuses in the embodiments of this application is not limited to performing functions in the order shown or discussed, but may also include performing functions substantially simultaneously or in the reverse order, depending on the functions involved. For example, the described methods may be performed in a different order than described, and various steps may be added, omitted, or combined. Additionally, features described with reference to certain examples may be combined in other examples.

[0082] From the above description of the embodiments, those skilled in the art can clearly understand that the methods of the above embodiments can be implemented by means of computer software products plus necessary general-purpose hardware platforms, and of course, they can also be implemented by hardware. The computer software product is stored in a storage medium (such as ROM, RAM, magnetic disk, optical disk, etc.) and includes several instructions to cause the terminal or network-side device to execute the methods described in the various embodiments of this application.

[0083] The embodiments of this application have been described above with reference to the accompanying drawings. However, this application is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other implementations under the guidance of this application without departing from the spirit and scope of the claims. All of these implementations are within the protection scope of this application.

Claims

1. A lightweight design method for a two-force lever control arm, characterized in that, include: Based on the vehicle parameters, determine the stiffness target of the control arm in the two-force member direction; The initial topology space of the control arm is determined, and the stiffness of the initial topology space is analyzed to verify whether the stiffness of the initial topology space meets the stiffness target. In response to the stiffness of the initial topology space satisfying the stiffness target, the initial topology space is optimized with the stiffness target as a constraint and the volume minimization of the control arm as the optimization objective, to generate the preliminary structure of the control arm. The topology optimization process includes at least setting minimum member size constraints and setting no-hole constraints. The preliminary structure of the control arm is smoothed and engineered to determine the target control arm structure; The stiffness and strength of the target control arm structure are simulated and analyzed to verify its stiffness and strength performance. In response to the fact that the rigidity and strength performance meets the preset requirements, a process simulation analysis is performed on the target control arm structure to evaluate the process feasibility of the target control arm structure and predict manufacturing defects.

2. The lightweight design method for the two-force bar control arm according to claim 1, characterized in that, Determining the initial topology space of the control arm includes: The motion envelope of the peripheral components of the control arm is extracted using kinematic simulation software. After removing the motion envelope and reserved gap from the vehicle assembly space, the space connecting the hard points on both sides of the control arm and the area near the hard points forms the initial topological space. The hard point is the theoretical connection point of the control arm in the vehicle suspension system, located at the center of the bushings at both ends of the control arm, and is used to determine the arrangement orientation of the control arm and the direction of the two force members.

3. The lightweight design method for the two-force bar control arm according to claim 2, characterized in that, The stiffness analysis of the initial topological space includes: The initial topological space is divided into a three-dimensional solid mesh, and rigid elements are established with the two hard points as the main points and the nodes in the three-dimensional solid mesh adjacent to the hard points as the slave points. A constraint is applied at one hard point, and a predetermined load is applied at the other hard point along the direction of the two-force member. The displacement of the hard point on the other side in the direction of the two-force member can be obtained by solving the problem. In response to the displacement being less than or equal to the ratio of the predetermined load to the stiffness target, it is determined that the stiffness of the initial topological space satisfies the stiffness target.

4. The lightweight design method for the two-force bar control arm according to claim 1, characterized in that, The topology optimization process includes at least setting a draft direction or parting surface to limit the forming direction of the topology optimization result.

5. The lightweight design method for the two-force bar control arm according to claim 1, characterized in that, The engineering process includes adjusting the dimensions of the target control arm structure and increasing the machined surfaces.

6. The lightweight design method for the two-force bar control arm according to claim 1, characterized in that, The process simulation analysis includes casting forming process simulation analysis; The process simulation analysis of the target control arm structure includes: The target control arm structure is specified as a cast part, the process type and material of the target control arm structure are selected, and the pouring temperature, mold preheating temperature and gravity direction are set. Establish a gating system and generate a mold; Set process parameters, divide the grid, and run the simulated filling and solidification process of the target control arm structure; The results of the simulated filling and solidification process were analyzed to identify defects such as shrinkage porosity, shrinkage cavities, air entrapment, and cold shuts.

7. The lightweight design method for the two-force bar control arm according to claim 1, characterized in that, The process simulation analysis includes forging forming process simulation analysis; The process simulation analysis of the target control arm structure includes: Based on the target control arm structure, establish pre-forging die, final forging die and billet models; Select the process type, forging type, and solver for the target control arm structure, and set the forging material and die temperature for the target control arm structure; Set the press type, friction and heat exchange parameters, generate a mesh, and set the time step and termination conditions; Check the fill rate, flow vector, and equivalent strain to identify defects such as incomplete filling, folds, and cracks.

8. A lightweight design system for a two-force lever control arm, characterized in that, include: The determination module is configured to determine the stiffness target of the control arm in the two-force member direction based on vehicle parameters; The verification module is configured to determine the initial topology space of the control arm and perform stiffness analysis on the initial topology space to verify whether the stiffness of the initial topology space meets the stiffness target. The response module is configured to respond to the stiffness of the initial topology space satisfying the stiffness target, and to perform topology optimization on the initial topology space with the stiffness target as a constraint and the minimization of the volume of the control arm as the optimization objective, to generate the preliminary structure of the control arm. The topology optimization process includes at least setting minimum member size constraints and setting no-hole constraints. The processing module is configured to perform smoothing and engineering processing on the preliminary structure of the control arm to determine the target control arm structure; The verification module is configured to perform stiffness and strength simulation analysis on the target control arm structure in order to verify the stiffness and strength performance of the target control arm structure. The analysis module is configured to perform process simulation analysis on the target control arm structure in response to the stiffness and strength performance meeting preset requirements, so as to evaluate the process feasibility of the target control arm structure and predict manufacturing defects.

9. An electronic device, characterized in that, include: A processor and a memory, the memory storing a program or instructions executable on the processor, the program or instructions, when executed by the processor, implementing the steps of the lightweight design method for a two-force lever control arm as described in any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, The readable storage medium stores a program or instructions that, when executed by a processor, implement the steps of the lightweight design method for a two-force lever control arm as described in any one of claims 1 to 7.

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