论文总字数：22449字

摘 要

本文以某轻型客车的扭杆弹簧和前减振器总成关键件为研究对象，利用有限元方法研究扭杆弹簧和减振器关键件活塞杆在极限工况下应力、应变和位移分布情况，为提高扭杆弹簧和减振器的可靠性提供依据，主要研究内容如下：

首先，建立扭杆弹簧和活塞杆三维实体模型。利用Handy Scan三维激光扫描仪获取扭杆弹簧和活塞杆表面点的三维坐标值。再使用Geomagic studio软件对获取的数据进行一系列数据处理获取扭杆弹簧和活塞杆的点云数据。并基于扭杆弹簧和活塞杆点云数据CATIA软件中QSR模块、创成式外形设计模块做表面的拟合，通过各表面的求交与拼接等逻辑运算最终获取扭杆弹簧和活塞杆三维实体模型。

其次，精确的建立扭杆弹簧和活塞杆有限元模型。先将优化过的扭杆弹簧和活塞杆三维实体模型导入有限元前处理软Hypermesh,为保证有限元强度与刚度计算得以顺利进行，划分网格前对扭杆弹簧和活塞杆模型进行几何清理。再对扭杆弹簧和活塞杆实体模型进行初步有限元网格划分，进而geom面板中相关命令细化接触区部分，最终得到了精细化的扭杆弹簧和活塞杆有限元模型。

最后，研究扭杆弹簧在客车满载条件下以及活塞杆在减振器处于伸张行程下应力、应变和位移分布情况。基于扭杆弹簧和活塞杆有限元模型的基础上定义扭杆弹簧和活塞杆的材料属性，以实际工况加载边界条件，对扭杆弹簧和活塞杆施加相应的载荷及约束，并通过Hyperview软件计算扭杆弹簧在满载条件下最大扭转切应力以及活塞杆在减振器处于伸张行程的最大拉伸应力。

计算结果表明扭杆弹簧和活塞杆的刚度强度均满足设计要求。

关键字：扭杆弹簧；减振器总成关键件；有限元法；刚度；强度

Calculation of Strength and Stiffness of Torsion Spring and Key Parts of Front Shock Absorber Assembly of Light Bus

Abstract

This paper takes the torsion bar spring and the key parts of the front shock absorber assembly of a light passenger car as the research object, and uses the finite element method to study the distribution of stress, strain and displacement of the torsion bar spring and the key parts of the shock absorber piston rod under the extreme conditions To provide a basis for improving the reliability of torsion bar springs and shock absorbers, the main research contents are as follows: First, establish a three-dimensional solid model of torsion bar springs and piston rods. Use the HandyScan 3D laser scanner to obtain the 3D coordinate values ​​of the torsion bar spring and piston rod surface points. Then use Geomagic studio software to perform a series of data processing on the obtained data to obtain the point cloud data of the torsion bar spring and the piston rod. Based on the torsion bar spring and piston rod point cloud data, the QSR module and the generative shape design module in CATIA software are used for surface fitting, and the torsion bar is finally obtained through logical operations such as intersection and splicing of each surface Three-dimensional solid model of spring and piston rod.

Secondly, the finite element model of the torsion bar spring and the piston rod is accurately established. The optimized torsion bar spring and piston rod three-dimensional solid model are first imported into the finite element preprocessing software hypermesh. To ensure that the finite element strength and stiffness calculations can be carried out smoothly, the torsion bar spring and piston rod models are geometrically cleaned before meshing. Then make a preliminary finite element meshing of the torsion bar spring and piston rod solid models, and then refine the contact area part of the relevant commands in the geom panel, and finally obtain a refined torsion bar spring and piston rod finite element model.

Finally, the distribution of stress, strain and displacement of the torsion bar spring under full load of the bus and the piston rod under the extension stroke of the shock absorber are studied. Based on the finite element model of torsion bar spring and piston rod, the material properties of the torsion bar spring and piston rod are defined, the boundary conditions are loaded under actual working conditions, and the corresponding loads and constraints are applied to the torsion bar spring and piston rod. Calculate the maximum torsional shear stress of the torsion bar spring under full load and the maximum tensile stress of the piston rod in the extension stroke of the shock absorber.

The calculation results show that the torsion bar springs and piston rods meet the design requirements.

Keywords: torsion bar spring; key parts of shock absorber assembly; finite element method; stiffness; strength

目录

摘要 I

Abstract II

第一章 绪论 1

1.1课题研究的目的与意义 1

1.2国内外发展状况 1

1.2.1国内外减振器发展状况 1

1.2.2国内外扭杆弹簧发展状况 2

1.2.3国内外有限元发展状况 2

1.3课题研究的主要内容 3

第二章 扭杆弹簧设计 5

2.1扭杆弹簧概述 5

2.2扭杆弹簧主要参数计算 5

2.2.1汽车整车基本计算参数的确定 5

2.2.2扭杆主要参数计算 6

2.3扭杆弹簧强度校核 9

第三章 减振器设计 10

3.1减振器的概述 10

3.2减振器的设计思路 10

3.3减振器参数和主要尺寸确定 11

3.2.1汽车整车基本计算参数的确定 11

3.2.2减振器主要参数计算 11

3.4活塞杆的强度校核 14

第四章 扭杆弹簧和减振器关键件三维建模 16

4.1逆向工程概述 16

4.2硬件扫描 16

4.3点云数据处理 17

4.3.1Geomagic Studio的简要介绍 17

4.3.2处理点云数据 17

4.4曲面重构及实体化 17

4.4.1曲面重构及实体化步骤 17

4.4.2扭杆弹簧和减振器总成关键件三维实体模型 18

第五章 Hypermesh有限元分析 21

5.1Hypermesh概述 21

5.2扭杆弹簧和活塞杆的CAE模型获取 21

5.3扭杆弹簧有限元分析 22

5.4活塞杆的有限元分析 27

第六章 总结与展望 33

参考文献 34

致谢 36

第一章 绪论

1.1课题研究的目的与意义

当前，中国的汽车市场对于各类车型的汽车的需求量一直在增加，汽车的产量只会持续升高^[1]，这就引起人们对于汽车性能提升的持续关注，所以汽车的相关性能技术以及对汽车性能的研究分析应随着汽车产业的发展而发展，这就需要科研人员制定更加合理的汽车零部件设计方案，从一般的整车开发设计，逐渐延伸到某些关键零部件的优化设计上，以提高汽车的整车性能。

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