基于数值仿真的十字型内高压成形吸能盒优化设计

目的 实现吸能盒的高碰撞吸能性和低成本化设计。方法 以传统的方形冲焊结构吸能盒为研究对象，将其优化为十字型冲焊和十字型内高压成形结构吸能盒，并利用成形数值仿真技术对十字型内高压成形吸能盒进行了成形性研究，还利用碰撞数值仿真技术对3种吸能盒结构进行了碰撞性能研究。结果 为提高碰撞吸能性，将传统方形冲焊结构吸能盒的4条主吸能常规传力路径，优化为十字型冲焊和十字型内高压成形结构吸能盒的12条主吸能传力路径，十字型内高压成形吸能盒同时能实现减重6.4%;利用成形数值仿真技术对十字型内高压成形吸能盒进行了成形性研究，结果显示十字型内高压成形吸能盒通过一模十二件生产，能具备优良的可制造性和经济性，相比方形冲焊吸能盒，十字型内高压成形吸能盒可实现降成本5.7%;利用碰撞数值仿真技术对3种吸能盒进行正面100%碰撞和正面40%偏置碰撞性能研究，相比方形冲焊吸能盒，结果显示十字型内高压成形吸能盒吸收能量分别增加12.8%和32.0%，碰撞力峰值分别降低8.4%和39.2%，比吸能分别增加20.5%和41.0%。结论 相比方形冲焊吸能盒，十字型内高压成形吸能盒可实现轻量化、低成本和高碰撞吸能性，同时还兼具优良的可制造性的特点。

Optimization Design of Cross Shaped Hydroforming Energy Crashboxes Based on Numerical Simulation

The work aims to achieve high collision energy absorption and low-cost design of energy crashboxes. Traditional square punch welded energy crashboxes were optimized into cross shaped punch welded and cross shaped hydroforming structures. The formability of the cross shaped hydroforming energy crashboxes was studied according to the forming numerical simulation technology, and the collision performance of three types of energy crashbox structures was studied according to the collision numerical simulation technology. To improve collision energy absorption, traditional square punch welded energy crashboxes usually of 4 main energy absorption and transmission paths were optimized to have 12 main energy absorption and transmission paths for cross shaped punch welded and cross shaped hydroforming structure energy crashboxes. The cross shaped hydroforming energy crashbox could achieve a weight reduction of 6.4% at the same time. The formability of the cross shaped hydroforming energy crashbox was studied according to the forming numerical simulation technology. The results showed that the twelve piece production of the cross shaped hydroforming energy crashbox with the first mock examination had excellent manufacturability and economy; Compared with square punching and welding energy crashboxes, cross shaped hydroforming energy crashboxes could achieve a cost reduction of 5.7%. Using the collision digital simulation technology, the performance of three types of energy crashboxes were studied for 100% collision and 40% offset frontal collision. The results showed that compared with square impact welding energy crashboxes, the energy absorption of cross shaped hydroforming energy crashboxes increased by 12.8% and 32.0%, respectively, and the peak collision force decreased by 8.4% and 39.2%, respectively. The specific energy absorption increased by 20.5% and 41.0%, respectively. In conclusion, compared with square punch welded energy crashboxes, cross shaped hydroforming energy crashboxes can achieve lightweight, low-cost, and high collision energy absorption, while also possessing excellent manufacturability.