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1、黑龍江工程學(xué)院本科生畢業(yè)設(shè)計(jì)黑龍江工程學(xué)院本科生畢業(yè)設(shè)計(jì) AThe significance of lightweightAutomotive lightweight main guiding principle: to ensure stability on basis of improved performance, energy-saving design of the assembly partscontinuous optimization model spectrum.The lightweight car, the car is to ensure strength and se
2、curity of the premise, as far as possible to reduce the cars curb weight, thereby enhancing the cars power, reducing fuel consumption and reduce exhaust pollution. Experiments show that if 10% of automobile weight reduction, fuel efficiency can bincreased by 6% -8%; vehicle curb weight is reduced by
3、 100 kg hundred kilometers can be reduced 0.3-0.6 liters; 1% of vehicle weight reduction, fuel consumption can be reduced 0.7 %. At present, due to the need for environmental protection and energy saving, lightweight car has become the world trend of automobile development.Lightweight car is the mai
4、n way:mainstream car models continue to optimize the size, specification size to retain the main parameters of the premise, to enhance the structural strength of the vehicle, reducing the amount of supplies;use of lightweight materials. Such as aluminum, magnesium, ceramic, plastic, fiberglass or ca
5、rbon fiber composite materials;The computer design. Such as finite element analysis, local reinforcement design;the use of load-bearing body, thinning the thickness of the body sheet metal.Among them, the current major automotive lightweight measures mainly the use of lightweight materials. for auto
6、motive lightweight design of the metal materialThe main vehicle through the cars lightweight materials to improve economy to contribute. Theoretical analysis and experimental results show thlightweight is to improve vehicle fuel economy and effective way. In order to equirements of lightweight vehic
7、les, some new material emerged and expanded the scope of application.Nonferrous AlloysTo passenger cars, the 1973 vehicle used by the non-ferrous alloy of the total timber weight ratio of 5.0% in 1980 to 5.6%, while in 1997 it reachNon-ferrous alloys in automotive applications is the rapid growth tr
8、end of development of automotive materials. AluminumSteel aluminum density of about 1 / 3 is the most widely used lightmaterials. United States production of automotive products, for example, aluminum alloy 1976 per vehicle is only 39kg, 1982 reached 62kg, while in 1998 it reach100kg.cast aluminum a
9、lloyMany elements can be used as cast aluminum alloy elements, only Si, Cu, Mg, Mn, Zn, Li in the mass production of great significance. Of course, widely used in the car is not thesimple binary alloy but also a variety of elements added to obtain a good overall performance.The automobile industry i
10、s the main market of aluminum castings, such as Japan, 76% of aluminum castings, aluminum die casting 77% of automotive castings. Mainly used in aluminum alloy engine block castings, cylinder heads, pistons, intake manifold, rocker arms, engine mount bracket, air compressor connecting rod, clutch ho
11、usings, clutch housings, wheels, brake parts, handles and cover shell-type parts and so on.Aluminum casting inevitably flawed, casting can not be heat treated produce a result in the use of higher strength aluminum alloy castings is limited. On the casting for this production process has been improv
12、ed, semi-solid casting forging forming method and method will be used to craft the future more.deformation of aluminum alloyRefers to deformation of aluminum alloy aluminum alloy plate and extrusions and forging materials, mainly used in automotive body panels on the boengine radiators, air conditio
13、ning condenser, evaporator, wheels, trim and suspension parts.As the effect is obvious lightweight, aluminum alloy car body applications is expanding. September 1990 as the Japanese started selling cars with a Honda NSX Unibody aluminum, cold rolled steel plate than in the same light 200kg body attr
14、acted worldwide attention. NSX to the entire vehicle with aluminum 31.3%, as in the aluminum car body, using the 6000 series alloy outer plate, inner plate with 5052-0 alloy, most use the 5182-0 alloy frame; that the side door of the strength and stiffness requirements are high, the use of the 6N01
15、alloy-based, appropriate adjustments to the Mg and Si content of the alloy. Also useful in Europe and America for 2036 and 2008 alloy plates inside and outside the body.Aluminum radiator originated in Europe and then throughout the world. In Europe, after the 1980s, aluminum radiator has occupied 90
16、% of the market. With? Car air conditioning, oil coolers, etc. The extensive use of aluminum heat exchangers market is rapidly expanding. From the material point of view, aluminum heat exchangers in a wide range of coating material applied to a large extent due to aluminum and aluminum cladding succ
17、essful development.aluminum matrix compositesLow density of aluminum matrix composites, strength and high modulus, good thermal fatigue properties, but in automotive applications by the price and production quality control and other constraints, have not formed a large scale. Currently, aluminum mat
18、rix composites in the connecting rod, piston, cylinder body holes, brake discs, brake calipers and other parts of the drive shaft tube test or showing superior performance, such as developed by Honda does not? Enhanced aluminum matrix composite wire rod steel rod down more than 30% weight on the 1.2
19、L gasoline engine can increase fuel economy 5%; using chilled aluminum powder and SiC powder (weight percentage of 2%) and mixed extruded into rods, forged with the shape of the piston rod for high strength can be 20% lower weight, engine power has increased significantly; composite enhanced with al
20、uminum piston head to cancel the first ring groove of austenitic cast iron inserts can drop weight 20%; aluminum matrix composite brake discs reduce weight than cast iron brake disc 50%.MagnesiumAluminum magnesium density of about 2 / 3, in the practical application of the metal is the lightest. Vib
21、ration absorption of magnesium alloy cutting ability is good, metal casting performance, it is suitable for manufacturing automotive parts.Most of the die casting magnesium alloy in the form of applications in the car, magnesium die casting aluminum production efficiency than the 30% to 50%. The new
22、ly developed non-porous casting method (Pore Free Diecast) can produce no holes and can be heat-treated magnesium die castings.Magnesium castings used in the car the earliest examples is the wheel rim. In the car on the trial or application instance there magnesium alloy clutch housing, clutch pedal
23、, brake pedal mounting bracket, dashboard frame, seat, steering column parts, steering wheel round core, transmission housing, engine mounts, cylinder head and cylinder head cover and so on. With the traditional system of the steering column bracket compared to the zinc, magnesium and heavy parts do
24、wn 65%; with traditional steel steering wheel core compared to 45 percent weight reduction of magnesium parts; compared with the aluminum cylinder head, magnesium parts 30% weight reduction; traditional stamping and welding structural steel brake pedal bracket compared to the overall weight of magne
25、sium castings down 40%, while its rigidity is also improved.Magnesium matrix composites has also made progress, with SiC particles as reinforcement, mixing technology is the use of liquid magnesium-based composite materials with good performance and lower production costs. In the AZ91 alloy by addin
26、g 25% SiC particle reinforced composites than the matrix alloy with 23% higher tensile strength, yield strength increased 47%, elastic modulus increased 72%.TitaniumTitanium density 4.5g/cm3, with high strength, high temperature strength and corrosion resistance and so on. Because titanium is expens
27、ive, since I saw the car in the luxury car and a small amount of individual applications. However, the application of titanium in the test car has a lot of research work. For example, with + titanium alloy of the engiconnecting rod system, the equivalent strength quenched and tempered steel 45 level
28、s, and weight can be reduced 30%; of titanium (Ti-13V-11Cr-3Al, etc.) and time by the strong cold treatment, intensity of up to 2000MPa, can be used to manufacture suspension springs, valve springs and valves, etc., and the tensile strength of 2100MPa of high strength steel than titanium springs can
29、 be 20% lower weight.The biggest obstacle to the application of titanium from its high price, Toyota Central Research Institute has developed a low-cost titanium matricomposites. The composite material to Ti-6Al-4V alloy matrix to the reinforcements powder metallurgy method of production, has been a
30、pplied in the engine connecting rod.附錄 B輕量化的意義汽車輕量化主要指導(dǎo)思想:在確保穩(wěn)定提升性能的基礎(chǔ)上,節(jié)能化設(shè)計(jì)各總成零部件,持續(xù)優(yōu)化車型譜。汽車的輕量化,就是在保證汽車的強(qiáng)度和安全性能的前提下,盡可能地降低汽車的整備質(zhì)量,從而提高汽車的動力性,減少燃料消耗,降低排氣污染。實(shí)驗(yàn)證明,若汽車整車重量降低10%,燃油效率可提高6% 8%;汽車整備質(zhì)量每減少100 公斤,百公里油耗可降低0.3 0.6 升; 汽車重量降低1%,油耗可降低0.7%。當(dāng)前,由于環(huán)保和節(jié)能的需要,汽車的輕量化已經(jīng)成為世界汽車發(fā)展的潮流。汽車輕量化的主要途徑是:汽車主流規(guī)格車型持續(xù)優(yōu)
31、化,規(guī)格主參數(shù)尺寸保留的前提下,提升整車結(jié)構(gòu)強(qiáng)度,降低耗材用量;采用輕質(zhì)材料。如鋁、鎂、陶瓷、塑料、玻璃纖維或碳纖維復(fù)合材料等;采用計(jì)算機(jī)進(jìn)行結(jié)構(gòu)設(shè)計(jì)。如采用有限元分析、局部加強(qiáng)設(shè)計(jì)等;采用承載式車身,減薄車身板料厚度等。其中,當(dāng)前的主要汽車輕量化措施主要是采用輕質(zhì)材料。可用于汽車輕量化設(shè)計(jì)的金屬材料車用材料主要通過汽車的輕量化來對燃料經(jīng)濟(jì)性改善作出貢獻(xiàn)。理論分析和試驗(yàn)結(jié)果都表明,輕量化是改善汽車燃料經(jīng)濟(jì)性的有效途徑。為了適應(yīng)汽車輕量化的要求,一些新材料應(yīng)運(yùn)而生并擴(kuò)大了應(yīng)用范圍。有色合金以乘用車來說,1973 年每輛車所使用的有色合金占全部用材的重量比為5.0%1980 年增至5.6%,而19
32、97 年則達(dá)到了9.6%。有色合金在汽車上應(yīng)用量的快速增長是汽車材料發(fā)展的大趨勢。鋁合金鋁的密度約為鋼的1/3 ,是應(yīng)用最廣泛的輕量化材料。以美國生產(chǎn)的汽車產(chǎn)品為例,1976 年每車用鋁合金僅39kg, 1982 年達(dá)到 62kg,而 1998 年則達(dá)到了100kg。( 1)鑄造鋁合金許多種元素都可以作為鑄造鋁合金的合金元素,但只有Si 、 Cu、 Mg、 Mn、Zn、 Li 在大量生產(chǎn)中具有重要意義。當(dāng)然,在汽車上廣泛應(yīng)用的并不是上述簡單的二元合金而是多種元素同時(shí)添加以獲得好的綜合性能。汽車工業(yè)是鋁鑄件的主要市場,例如日本,鋁鑄件的76%、鋁壓鑄件的77%為汽車鑄件。鋁合金鑄件主要應(yīng)用于發(fā)動
33、機(jī)氣缸體、氣缸蓋、活塞、進(jìn)氣歧管、搖臂、發(fā)動機(jī)懸置支架、空壓機(jī)連桿、傳動器殼體、離合器殼體、車輪、制動器零件、把手及罩蓋殼體類零件等。鋁鑄件中不可避免地存在缺陷,壓鑄件還不能熱處理,因此在用鋁合金來生產(chǎn)要求較高強(qiáng)度鑄件時(shí)受到限制。為此在鑄件生產(chǎn)工藝上作了改進(jìn),鑄造鍛造法和半固態(tài)成型法將是未來較多用的工藝。( 2)變形鋁合金變形鋁合金指鋁合金板帶材、擠壓型材和鍛造材,在汽車上主要用于車身面板車身骨架、發(fā)動機(jī)散熱器、空調(diào)冷凝器、蒸發(fā)器、車輪、裝飾件和懸架系統(tǒng)零件等。由于輕量化效果明顯,鋁合金在車身上的應(yīng)用正在擴(kuò)大。如1990 年 9 月開始銷售的日本本田NSX車采用了全鋁承載式車身,比用冷軋鋼板制造的同樣車身輕 200kg 引起全世界的矚目。NSX全車用鋁材達(dá)到31.3%,如在全鋁車身上,外板使用 6000 系列合金,內(nèi)板使用5052 0 合金,骨架大部使用5182 0 合金;由于側(cè)門框?qū)?qiáng)度和剛度要求很高,使用以6N01 合金為基礎(chǔ)、適當(dāng)調(diào)整了Mg和Si 含量的合金。在歐美也有用2036 和 2008 合金作車身內(nèi)外板的。鋁散熱器發(fā)源于歐洲而后遍及全世界。在歐洲,到20 世紀(jì) 80 年代后期鋁散熱器已占領(lǐng)市場的90%。隨?車用空調(diào)、油冷卻器等的大量使用,鋁熱交換器的市場迅速擴(kuò)大。從材料的角度看,鋁在熱交換器上的廣泛應(yīng)用在很大程度上歸功于包覆料覆層鋁板和鋁帶
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