重庆理工大学学报2025，Vol.39Issue(13)：1-8,8.DOI:10.3969/j.issn.1674-8425(z).2025.07.001
考虑多工况权重的重载汽车车架拓扑优化设计
Topology optimization design of heavy-duty vehicle frame considering multiple operating weights
摘要
Abstract
As the number of vehicles in China continues to rise,energy conservation and emission reduction have become ever more urgent.Against such a backdrop,the lightweight design of heavy-duty trucks plays a crucial role in cutting operational costs,effectively reducing environmental pollution,and improving transportation efficiency.The chassis,as a core structural component of heavy-duty trucks' load-bearing system,has a high mass proportion,and its mechanical performance directly impacts the overall vehicle safety and durability.Therefore,its lightweight optimization design is particularly important. However,in the complex and varied service scenarios,the chassis structure of heavy-duty trucks endures highly nonlinear and dynamically coupled complex loads.Traditional lightweight design methods often focus on a single or limited static loading condition,unable to adapt to the complex service environment,which may lead to designs with insufficient robustness or excessive safety redundancy.While existing research has made some progress,the coverage of loading conditions remains limited,often focusing on 3-4 static or quasi-static basic conditions and failing to fully consider the multi-dimensional and time-varying service load spectra that a vehicle may encounter over its entire lifecycle.Thus,a lightweight design method is urgently needed for chassis that fully integrates the load characteristics under various service conditions for heavy-duty trucks. To overcome the excessive mass in existing heavy-duty trucks,this paper proposes a topology optimization method based on the Analytic Hierarchy Process(AHP),which considers the weightings of multiple loading conditions for the lightweight design of heavy-duty truck chassis.First,static and torsional rig tests of the chassis are conducted using the DH5922 dynamic signal analysis system to obtain key mechanical performance data.Next,based on the actual load spectrum,eight typical service conditions for heavy-duty trucks are derived from common service scenarios.A high-precision finite element model is built and verified using the test data.Then,these eight typical service conditions are compared using AHP,and the weighting coefficients for each condition are calculated.A multi-condition topology optimization mathematical model is built to minimize the weighted structural flexibility,with constraints on the material volume fraction and maximum stress.Symmetry and minimum member size constraints are introduced to reduce costs.Finally,based on the optimized material distribution of the chassis,the topology optimization results are evaluated,and a lightweight design reconstruction of the chassis is completed.The optimization scheme undergoes comprehensive performance verification.Results show compared with the previous chassis structures,the optimized chassis reduces its weight by 7.41％(0.43 tons)to 5.37 tons.It meets the structural stiffness and strength requirements and fully considers the various loading conditions encountered by the heavy-duty trucks.关键词
车架/台架试验/轻量化/拓扑优化/有限元仿真Key words
frame/bench test/light weight/topology optimization/finite element simulation分类
交通工程引用本文复制引用
亓昌,陈亮,杨姝,肖杨..考虑多工况权重的重载汽车车架拓扑优化设计[J].重庆理工大学学报,2025,39(13):1-8,8.基金项目
国家重点研发计划课题(2022YFB2503503) （2022YFB2503503）
