Research on welding deformation control technology of battery electric vehicle framed aluminum body

IF 4.8 2区材料科学 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Progress in Natural Science: Materials International Pub Date : 2024-02-01 DOI:10.1016/j.pnsc.2024.02.002

Bo Liu , Jian Yang , Jia Li , Xiaolin Liao , Qin Yang , Jinsheng Zhang , Tiegang Hu , Shuxun Jiang

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Abstract

The welding process of aluminum (Al) alloy car body has problems such as poor weld quality, low welding coefficient, and large welding deformation. This paper mainly focuses on material accuracy design, lap structure design, simulation, and process manufacturing to break through the precision control problems caused by welding deformation of battery electric vehicle Al alloy car body. First, the 209 key functional dimensional chains of Al body-in-white are analyzed and decomposed to component and profile tolerance dimensions step by step. Moreover, the differences of vertical butt, bevel butt, and plug structures are studied and joint matching is implemented in a targeted manner. Subsequently, through welding deformation simulation analysis and welding sequence optimization, the body-in-white welding process and tooling fixtures are guided and designed to ensure that the dimensional accuracy of the Al body is controlled to ±2 mm in all aspects. Finally, the design of the whole vehicle arrangement of mechanical, human-machine, and major components is carried out, and an all-Al framed battery electric vehicle lightweight platform with different sizes and ranges is innovatively created. The difficulties such as the contradiction between power battery size and arrangement space, unreasonable arrangement position, and load distribution are solved.

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电池电动车框架铝车身焊接变形控制技术研究

铝合金车身焊接工艺存在焊接质量差、焊接系数低、焊接变形大等问题。本文主要从材料精度设计、搭接结构设计、模拟仿真、工艺制造等方面入手，突破电池电动车铝合金车身焊接变形引起的精度控制难题。首先，分析了铝合金白车身的 209 个关键功能尺寸链，并逐步分解到部件和型材公差尺寸。此外，还研究了垂直对接、斜面对接和插接结构的差异，并有针对性地实施了接头匹配。随后，通过焊接变形仿真分析和焊接顺序优化，指导和设计白车身焊接工艺和工装夹具，确保铝车身各方面尺寸精度控制在±2 毫米。最后，进行整车机械、人机、主要零部件布置设计，创新性地打造出不同尺寸、不同续航里程的全铝框架电池电动车轻量化平台。解决了动力电池尺寸与布置空间的矛盾、布置位置不合理、载荷分布不均等难题。

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来源期刊

Progress in Natural Science: Materials International 综合性期刊-综合性期刊

CiteScore

8.60

自引率

2.10%

发文量

2812

审稿时长

49 days

期刊介绍： Progress in Natural Science: Materials International provides scientists and engineers throughout the world with a central vehicle for the exchange and dissemination of basic theoretical studies and applied research of advanced materials. The emphasis is placed on original research, both analytical and experimental, which is of permanent interest to engineers and scientists, covering all aspects of new materials and technologies, such as, energy and environmental materials; advanced structural materials; advanced transportation materials, functional and electronic materials; nano-scale and amorphous materials; health and biological materials; materials modeling and simulation; materials characterization; and so on. The latest research achievements and innovative papers in basic theoretical studies and applied research of material science will be carefully selected and promptly reported. Thus, the aim of this Journal is to serve the global materials science and technology community with the latest research findings. As a service to readers, an international bibliography of recent publications in advanced materials is published bimonthly.