Cast Front Side Frame Structure for Frontal Impact Bending Resistance
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Solution Overview
Problem
Conventional automobile front side frames, whether hollow or formed from cast aluminum, struggle to effectively absorb impact loads during frontal collisions due to bending, compromising occupant protection and rigidity.
Innovation Solution
A vehicle frame with a cross-sectional H-shape, featuring bulging portions and integrated ribs, is molded by casting to enhance rigidity without increasing component count, allowing it to absorb impact loads without bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the front side frame is formed by a cast member that is made of an aluminum alloy and is integrally provided with a front damper housing, then there is an effect of reducing the number of components, but it is difficult to obtain a hollow structure from a front end to a rear end of the front side frame due to a mold structure. For this reason, it is likely to be bent by the impact load from the front
Solution Approach 1:
The front side frame is divided into multiple sections with different structural characteristics: a hollow section for impact resistance and a solid cast section for component integration. This segmentation allows each part to be optimized for its specific function while being manufactured as a single piece.
Solution Approach 2:
Different portions of the front side frame have different structural qualities - the front end features a hollow structure for impact absorption, while the rear end maintains a solid cast structure for integrating the damper housing. This local differentiation resolves the contradiction between component reduction and impact resistance.
2Strength
If the front side frame has the hollow structure as in the conventional general automobile, then the structure is less likely to be bent by the impact load from the front, but the number of components increases
Solution Approach 1:
The invention merges the hollow structural function with the solid cast function into a single integrated front side frame. The hollow section provides impact resistance while the solid section integrates the damper housing, eliminating the need for separate components.
Solution Approach 2:
The front side frame serves multiple functions simultaneously: it provides structural support, absorbs impact loads through its hollow section, and integrates the damper housing through its solid cast section. This multi-functionality reduces the overall number of components needed in the system.
Data Source
AI summary
A front side frame that is integrally molded by casting has: a horizontal plate portion; a first vertical plate portion that continues from one end portion in a width direction of the horizontal plate portion and extends to both sides in a thickness direction of the horizontal plate portion; and a second vertical plate portion that continues from another end portion in the width direction of the horizontal plate portion and extends to both of the sides in the thickness direction of the horizontal plate portion. The horizontal plate portion has a bulging portion.