Journal of Jilin University(Engineering and Technology Edition) ›› 2023, Vol. 53 ›› Issue (5): 1282-1288.doi: 10.13229/j.cnki.jdxbgxb.20210920

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Influence of lap welds on the lightweight design of welded aluminum structures

Xin CHEN1(),Guan-chen ZHANG1,Kang-ming ZHAO1,Jia-ning WANG1,Li-fei YANG1,De-rong SITU2   

  1. 1.State Key Laboratory of Automobile Simulation and Control，Jilin University，Changchun 130022，China
    2.School of Mechanical and Traffic Engineering，Guangxi University of Science and Technology，Liuzhou 545006，China
  • Received:2021-09-14 Online:2023-05-01 Published:2023-05-25

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Abstract:

In order to study the effect of Molten inert gas welding（MIG） lap weld on the lightweight design of aluminum alloy welded structure， the equivalent model of shell element was established through tensile of welding seam， and it was applied to the lightweight design method based on multi-objective optimization of structural parameterized model. The results show that after considering the influence of weld， the results are closer to the engineering practice， the performance of each target is optimized， besides the reasonable distribution of stress at the weld and a more ideal weld layout are realized， but with increased quality. Therefore， the lightweight design method of welding structure of aluminum alloy considering the effect of MIG lap weld has better engineering practical application significance.

Key words: vehicle engineering, aluminum alloy welded structure, weld shell element model, parametric model, multi-objective optimization

CLC Number: 

  • U46

Fig.1

Parameterized model of aluminum alloy welding structure"

Table 1

Application of loads and boundary conditions in various working conditions"

工 况固定带载荷施加弧板载荷施加
向前8倍静载载荷垂直向上2.25 mg垂直向下2.75 mg，前半部分加载向前4 mg
8倍静载侧向载荷垂直向上2.25 mg，水平侧向1.6 mg垂直向下2.75 mg，水平侧向2.4 mg
8倍静载垂直向上垂直向上4 mg-
向前10g加速度载荷垂直向上2.25 mg垂直向下2.75 mg，前板部分加载向前5 mg
向后10g加速度载荷垂直向上2.25 mg垂直向下2.75 mg，后板部分加载向后5 mg
5g侧向加速度载荷垂直向上2.25 mg，水平侧向1.6 mg垂直向下2.75 mg，水平侧向1.5 mg

Fig.2

Schematic diagram of position of fixed belt and arc plate"

Fig.3

Experimental design process on Isight"

Fig.4

Plot of contribution of position variables to maximum displacement response"

Table 2

Comparison of the accuracy of three approximate models"

项目响应面模型径向基神经网络模型克里格模型
R-SquareRMSAverageR-SquareRMSAverageR-SquareRMSAverage
误差要求>0.9<0.2<0.2>0.9<0.2<0.2>0.9<0.2<0.2
质量1.000.000.001.000.010.010.000.240.20
最大位移1.000.000.000.990.030.030.000.250.19
最大应力0.810.060.040.930.100.060.770.110.09
一阶模态1.000.010.010.920.120.090.000.360.34

Fig.5

Tensile specimen of lap weld"

Fig.6

Weld failure form"

Table 3

Related mechanical properties of three sets of welds"

焊接形式屈服强度 /MPa抗拉强度 /MPa泊松比弹性模量 /GPa
Ⅰ型焊缝106.99155.660.360
Ⅱ型焊缝88.84111.720.350
Ⅲ型焊缝95.02154.420.360

Fig.7

Equivalent model of lap weld shell element"

Fig.8

Comparison of simulation and experiment of welding seam equivalent model"

Fig.9

Maximum stress at weld under 10g forward acceleration load"

Fig.10

Parametric model and weld design variables"

Table 4

Comparison of optimization results of design variables"

变量描 述原优化结果/mm考虑焊缝的优化结果/mm
T1鞍座厚度9.110.0
T3前竖梁厚度6.26.0
T4后竖梁厚度6.66.4
T6固定带厚度5.46.2
T8前板厚度44.9
T9后板厚度4.64.0
T10底座厚度4.14.0
L1前板X向移动-20-20
L2前板Z向移动-10+1
L3后板X向移动+20+20
L4后半Z向移动-10-10
S3固定带宽度-10-10
S4前板加强筋长度+5-2
S5后板加强筋长度+4+5
S6前板上端Z向移动0-8
S8后板上端Z向移动+6+18
L8鞍座焊缝间距-+10
L9底座焊缝间距--45

Table 5

Comparison of optimized performance of aluminum alloy welding structure"

性 能原支架结构无焊缝多目标优化支架考虑焊缝多目标优化目标值
最大位移/mm8倍前0.6190.6910.657<13
8倍侧2.3082.0981.920<13
8倍上1.2621.3121.264<13
最大应力/MPa10g前104.343110.612115.081<130
10g后83.943109.750115.253<130
5g侧161.867123.098122.614<130
一阶模态/Hz25.9328.4928.73>25
质量/kg64.8561.3365.14Min
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