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Hot stamping door impact beams Experimental studies and material properties gradient optimization

Author: HuKangKang
Tutor: PengXiongQi
School: Shanghai Jiaotong University
Course: Materials Processing Engineering
Keywords: Optimization Hot stamping Response surface methodology Door impact beams FEM
CLC: U467.3
Type: Master's thesis
Year: 2012
Downloads: 248
Quote: 1
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With the increase in car ownership in China and the rapid development of road traffic, car traffic conditions in a variety of collisions also on the rise. Which is the most frequently occurring side collision and accidents causing casualties form the largest one. Is the side of the car door, the intensity is relatively weak. In the collision process, the inner door panel intrusion speed and distance is caused by the occupant intrusion leading causes of injury, how to reduce the intrusion of the door inner panel is to improve the speed and distance invasive car side impact safety an important way. Door impact beam as a reinforcing member to resist the door side impact, it can greatly reduce the degree of deformation of the side door, which can reduce vehicle collision on the car occupant injury. So the door inside door impact beams to optimize the design and improve the rigidity of the door, thereby increasing the vehicle side crash safety, to improve occupant safety protection and improvement of road traffic safety has a very important significance. In order to improve door impact beams anti-collision capability to improve its energy absorption properties, and thus enhance the security side of the car, this paper proposes the use of ultra high strength steel custom thermoforming technology manufacturing strength uneven distribution of single thickness door impact beams. To make the custom thermoformed material door impact beam gradient rationalize the use of LS-OPT and LS-DYNA simulation was carried out based on the optimal design. Numerical optimization based on response surface method, the use of components crash simulation analysis, custom thermoforming door impact beam gradient material properties to optimize the design. Firstly, in the hot stamping process analysis, based on the intensity level after a hot stamping were 1.5GPa, 1.7GPa, 1.9GPa, 2.2GPa hot forming martensite steel as raw material, design and manufacture of hot stamping dies, carried out preparation of small quantities of hot stamping parts. By adjusting the process parameters optimization of hot stamping process, a successful trial to meet the performance requirements of the hot stamping door impact beams. Using optical microscopy, micro hardness tester and universal tensile testing machine and other analytical testing methods for forming parts of microstructure and mechanical properties were analyzed. Then, the paper and the U.S. FMVSS214 and other reference GB15743 door strength testing standards prepared hot forming bumper beams hydrostatic strength test. Based on the above experiments, the use of Hypermesh and LS-DYNA finite element modeling and boundary conditions on the hydrostatic strength test procedure for finite element simulation analysis through the simulation results and experimental results were analyzed to verify the finite element model correctness and reliability. Finally, the bumper beam simulation results as a basis for optimal design, using parts crash simulation analysis, in order to make a single thickness of the door impact beam material properties gradient optimization design. According to parts of the collision safety requirements to determine optimal design model objectives, design variables and constraints, etc.; using Latin Hypercube Sampling design space in the variable selected sample points test; according to the results based on response surface methodology to establish the quadratic polynomial door impact beams response surface model; through genetic optimization algorithm to get the door impact beam to optimize the distribution of material properties. The results show that the optimized variable intensity door impact beams ensure crashworthiness under the premise of improving the door impact beam energy absorption effect, can the crew in the event of an accident to provide more effective protection. In this paper, automotive door impact beams for material performance gradient optimized design, within a certain range to obtain an optimal distribution of material bumper beams, as well as to improve the car door on the side of the vehicle crashworthiness performance. The research method is versatile, and can be widely used in various models of door impact beams.

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