GMT材料在轿车轻量化设计中的应用

上海交通大学硕士学位论文GMT材料在轿车轻量化设计中的应用姓名：赵勇申请学位级别：硕士专业：车辆工程指导教师：沈利冰;胡敏20090401IGMTGMTGMTGMTGMTGMT1GMTGMTGMTII2GMTGMT3GMTECER42RCARGMTGMTIIITHEAPPLICATIONOFGMTMATERIALINAUTOMOTIVELIGHT-WEIGHTDESIGNABSTRACTAutomotivelightweightstructuredesignandautomotivepassivesafetybecomemoreandmoreconcernedallovertheworld.AutomotiveMaterialsarethebasisofautomotivedesignandcompetition,thedevelopmentofautomobiletechnologydependsonthedevelopmentofnewmaterials.Inrecentyears,aluminumalloy,highstrengthsteel,syntheticplastic,compositematerialsandceramicsareusedmoreandmorewidelyintheautomotiveindustry.Inthispaper,basedonthelightweightstructuredesignandautomotivepassivesafety,themanufactureprocessofGMTpartandtheapplicationofGMTmaterialonbumperbeamdesignarediscussed.First,thepaperpresentssomebasicideas,applicationsanddevelopmentinlightweightstructure,newmaterialsandautomotivepassivesafety.ThentheperformanceofGMTmaterialisresearchedandsomeworkaboutmanufactureprocessandmoldingmethodisdone.Atlast,abumperbeammodelforFEAanalysisisbuiltandtheresultsareusedinIVGMTmaterialapplication.Themainresearchworksarefocusedinthefollowingaspects:1.TheperformanceandmanufactureofGMTmaterial.TheperformanceofGMTmaterialisdiscussed,manufactureandmoldingprocessisresearched.ThisisabasicstudyforapplicationofGMTmaterial.2.GMTpartmanufactureprocessandparameteranalysis.Bymanufacture,moldingandparameteranalysis,theheatandmoldingprocessarediscussed.3.FEAanalysisofbumperbeamforpassivesafety.AFEAmodelofbumperbeamisbuilt.TheFEAanalysisisdonebasedontheECER42andRCARspecification.TheresultsvalidatedtheapplicationofGMTonbumperbeam.Keywords:GMT,lightweight,bumperbeam,FEAanalysis11.11.1.1[1][1]21.1.2a)GMTb)GMT1.21.2.1,35%7%15%16%18%35%1%2%3%3%1-1Fig1-1Petroloverallapplication2020%-2615%29%13%1331100%20%29%3201080%-85%75%-80%1.2.22020%-26%1990()()()11991-199920052002124kg80P200037421152019903kg20AMAZASAZ91DAEMgAlCaMgAlCaReAJZAC8506MRI201SMRI202SMRI203S13SUV/AB54(210N/mm2)(550N/mm2()&10PNGVClass218kg)()&&340N/mm2550N/mm21998912004285280N/mm210420086059025kg/AISI300AISI200#AISI300AISI204MLPG306AISI204MAISI301;,,[2]1.3:,,,,,,,,1)2):FiatRenzoPorroAlfaRomeo156FiatTeksid,Meridian,Lear30-50%[3],,4mm530%[4]GEPlasticsDarinEvans7IM-PC/PBTBM-PC/PBTCM-GMTBM-HDPEEPPPC/PBTGMT[5]3MLorenD.LarsonDoldL.RobertsonSMC[6]AZDELEnamulHaqueFMVSS201HIC1000LD-GMTCAELD-GMT[7]DaimlerChryslerNVHA[8]FRPFRPFRI[9]GMTGMT[10]:,SMCGMTGMTGMTGMT1.48GMTGMTGMTGMT,GMT1,2/()3(GMT),,4,,().91-2Fig.1-2TopicstudyflowchartGMTGMTGMTGMTGMT101)2)2.11.19941835ULSAB[11](UltraLightSteelAutoBody)ULSAB(HSS)(AHSS)(2)(TailoredBlanks)(3)(FEM)ULSAB199851-111ULSAB25%,80%52%58%,15%19975ULSAC[12](UltraLightSteelAutoClosuers).ULSAS(UltraLightSteelAutoSuspension)19991ULSAB_AVC(AdvancedVehicleConcepts)ULSABULSAC1211519%-32%oULSAC33%0ULSASI3l12%20%-30%30%a2000ULSAB_AVC(012004CULSABAVCULSAB_AVC2-22.[13]47%13%40%40%A2895kg43%A8ASF(AluminumSpaceFrame)Z812a)b)c)d)e)f)g)3.CAE4007530%A61.1mmHondaInsight37%2.2197390%55%60%12%15%65%8%12%6%10%4%133%10%199020005kg270kg0kg40kg900kg200kg115kg200kg30kg0kg35%1.[14]201070%[15]2-1Fig.2-1High-TensileSteelapplicationonNewAccord2.,a)1/33360%50%[16]80143%7%[17]b)18g/cm32/3200040Kg201080Kg2-2Fig.2-2Micro-alloyedSteelapplication3.1.0g/cm3[18][19]10%15%Smart15EspaceElise1998CCV95Kg[20]4.,,70%,60%,,,,(MMC)[21]40%[22]2.3GMTGMT(GlassMatreinforcedThermoplastics)GMT,2.3.1GMT16;;SMCGMTSMCSMC.SMCASMC50%SMCGMTGMT17GMT,50-300N/mm2GMTGMTGMT,2.3.2GMTGMTGMT2-3PPGMT2-3GMTFig.2-3GMTmanufactureprocessGMTGMT2-42-52-61GMT182-4Fig.2-4Continuousglassfibermat2GMT2-5Fig.2-5Uncontinuousglassfibermat3192-6Fig.2-6UnidirectionalfiberUD30%40%GMTGMTexGMT[23]2-7Fig.2-7GMTexchoppedglassfibre202.3.3GMT1.GMTGMTGMT:GMTGMTGMTGMTGMTPressformingFlowmolding1.1GMT1.2GMTGMT95%GMT2-8Fig.2-8BasicCompressionMolding21GMT2-8GMTGMT1232GMT1231000T42-9GMTFig.2-9GMTmanufactureline2.4GMTGMTGMTGMT22GMT1234GMTGMT3.1GMT3.1.1GMT1000/1400mmGMTGMT3-1GMTFig.3-1GMTblankdimension3.1.2GMTGMT23GMT3-2GMTFig.3-2GMTblanksizesandblanklayoutCAD3-3Fig.3-3GMTblanksizesandlayoutGMT40PP/3.7mm1.22g/cm20.45g/cm2)(45.0)(2cmceTotalsurfagpartweight=[23]GMT243.23.2.1GMT1231000T4,GMTGMT3.2.21GMTGMTGMT165C1GMT,3aGMTGMT253-4Fig.3-4Contactheatingb-GMTPP(polypropylene)GMTGMTGMTGMTGMTGMTGMTGMTGMTGMTGMTGMT3-5Fig.3-5InfraredovenGMT27aGMTbGMT205-230cGMTdGMTGMTePP3-7Fig.3-7Criticaltemperaturezones4GMTa180-240GMT220190-215GMTGMT240GMTGMTb5-8GMT240100-215GMT27aGMTbGMT205-230cGMTdGMTGMTePP3-7Fig.3-7Criticaltemperaturezones4GMTa180-240GMT220190-215GMTGMT240GMTGMTb5-8GMT240100-215GMT283-8Fig.3-8Threedifferentheatingprofiles5GMTGMTaGMT165CGMTGMT29bGMTGMTGMTcGMT2GMTGMTGMTGMTGMTPP,AGMT200215b40-65CDGMTGMT1)GMTGMT,GMT303-9GMTFig.3-9HandingandloadingofGMTblanksGMTaGMTbGMTCGMT20-80%GMT2)GMTGMT`GMTGMTGMT3-10GMTFig.3-10GMTblanksizeandplanklayoutGMTAB3GMT,,GMT31GMTGMTGMT2.5GMTGMTGMT[23]3-11Fig.3-11Threedifferentpressureandspeedprofile3.3GMT3.3.1GMTGMT30%GMT42%GMTGMT323-12Fig.3-12Materialproposal3.3.21.,(ab),c)PP3-13Fig.3-13Heatprocess100-110405180-200405GMT3323-14Fig.3-14RelationofPressstrokeandPressureprofileT1T2T3