Material-structure-process integrated design for cast aluminum alloy door

Journal Information

J. Hefei Univ. Tech. (Nat. Sci.), Jun.2025, Vol.48 No.6: 737-743

DOI: 10.3969/j.issn.1003-5060.2025.06.004

Authors

GU Xianguang $ ^{1} $, LIANG Wenyu $ ^{1} $, SHI Yongxiang $ ^{2} $

(1. School of Automobile and Traffic Engineering, Hefei University of Technology, Hefei 230009, China; 2. NIO Automotive Technology (Anhui) Co., Ltd., Hefei 230061, China)

Abstract and Keywords

Abstract: In order to achieve the goal of lightweight, this paper presents a material-structure-process integrated design for the rear door of an electric vehicle. Firstly, the multi-objective topology optimization under four common working conditions of the door is carried out, and the design space is analyzed. Secondly, the detailed design of the door is performed by combining the precision casting process and the material characteristics of ZL205A copper and aluminum alloy. Finally, the modal and stiffness performance analysis of the new door is conducted to verify the rationality of the structure. The trial production and performance testing experiments of the doors that meet the design requirements show that the new cast aluminum alloy doors meet the performance indicators while reducing the mass by 13.66%, achieving the lightweight design goal.

Keywords: door performance; precision casting; lightweight; integrated design; variable-weight topology optimization

作者信息

谷先广 $ ^{1} $，梁文宇 $ ^{1} $，施永祥 $ ^{2} $

(1. 合肥工业大学汽车与交通工程学院，安徽合肥 230009；2. 蔚来汽车科技（安徽）有限公司，安徽合肥 230061)

摘要和关键词

摘要: 为实现轻量化目标,文章针对某款电动汽车后门进行“材料-结构-工艺”的一体化设计。首先进行车门4种常见工况下的多目标拓扑优化,分析出设计空间;然后结合精密铸造工艺和ZL205A铜铝合金材料特性对车门进行详细设计;最后进行新型车门模态及刚度性能分析,以验证结构的合理性。对满足设计要求的车门进行试制和性能测试试验,结果表明,新型铸铝车门在满足各性能指标的同时,质量减轻13.66%,达成轻量化设计目标。

关键词: 车门性能；精密铸造；轻量化；一体化设计；变权拓扑优化

Funding

安徽省科技重大专项资助项目（202203a05020029）

合肥工业大学学报(自然科学版)

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