汽车悬架控制臂的开发一、引言1. 设计一个控制臂时，输入条件(1) 载荷条件：一般来讲，系统的载荷已知，但是零件的载荷难于确定(2) 控制臂的最大工作空间：进行控制臂尺寸设计的基本考虑点(3) 软件的选择：可以进行拓扑优化(Hyper-works, Ansys等)(4) A solider modeler：具有高级设计特征，来Capture拓扑优化以后的复杂特征(5) 形状优化软件：减轻重量，同时保持较低的应力水平。
2. 设计流程二、引言对各个步骤的详细解释Step 1A：确定控制臂的设计空间重要性：设计空间的大小与优化结果有关过小：优化的结果只是最优解的一个子集扩大：在一些载荷工况下面，这个部件可能和其它的部件重合。
方法：利用Pro/E 的Behavioral modeling (BMX) 确定设计空间Step 1B: 确定控制臂的载荷利用ADAMS建立悬架的模型，汽车在不同的行驶工况下。
作用在轮胎上的力已知，控制臂和车身或者转向臂的连接点已知。
由此可以确定作用在控制臂上的力。
（仅仅用于初始计算，由于控制臂的形状为初步的）Step 2 初步设计控制臂过重，利用了最大的设计空间，但是连接点的设计要准确。
Step 3: 拓扑优化目标：刚度最大，一阶固有频率最大等等。
约束：重量最轻，减小最大应力等等。
软件：Optistruc、Ansys等Step 4: 利用拓扑优化的结果进行二次设计(1) 考虑制造过程：锻造、铸造还是机加工。
(2) 在进行新的建模时，如何利用拓扑优化的结果Step 5 形状优化(Overall shape optimization)在进行拓扑优化时，没有加应力约束，此时需要进行形状优化。
Step 6：利用形状优化的结果进行第三次设计12% 的weight reduction; 13% stress reduction。
Step 7：考虑控制臂的柔性，确定作用在控制臂上的载荷控制臂的柔性可以改变作用在上面的载荷。
计算发现，考虑控制臂的柔性以后，作用在控制臂上载荷的改变可以达到＋/－33％，从而可能导致Fatige的改变。
Step 8：最终设计－部分拓扑优化和部分形状优化液锻和铸锻控制臂性能的比较A comparative study between two families of front lower control arms manufactured via. Cast-Forge and NRC (New Rheocasting Process) was carried out at Citation Corporation to understand the process capabilities of NRC in automotive suspension applications.一、研究背景目的：A benchmarking research and development program was funded and carried out within Citation Corporation to evaluate and confirm process capabilities of NRC, as well as its feasibility and competitiveness in automotive suspension applications.方法：●Reverse engineering the existing Cast-Forge control arm●Analyze the existing component to establish baseline for comparativestudy●Develop concept design for NRC●Optimize prototype design for weight, performance, andmanufacturability●Utilize process simulation to help establish process parameters●Manufacture prototype control arms●Bench test both families of control arms for materials evaluation andcomponent performance●Analyze test results;Lessons learned assessment二、比较研究的步骤和内容1. 逆向工程对目前供应商的样件进行测绘2. 基NRC制造的控制臂的概念设计The prototype design was intended to be conservative in structural performance, but aggressive in exploring manufacturing process capability. It has relatively long thin-walled H-section arms resulting much improved fore/aft stiffness while maintaining the same weight as the existing control arm. The effects of this design concept on process capability will be discussed in detail in the next two sections.3. 基于NRC的控制臂的制造（1）计算机模拟Figure 4的模拟结果与Figure5的实际制造情况具有较好的一致性。
（2）X射向检查有无气孔4. Slug (毛坯、连皮) material analysis检验材料的均匀性To understand the quality of the NRC slurry material that was introduced into the die cavity to form the part, some preliminary microstructure and chemical analysis were carried out. Figure 7 describes the sample location out off a typical slug.5. 材料的性能Tensile specimens have been cut from both families of control arms. The tensile test results are tabulated in the following table:6. 结构分析与控制臂的性能实验（1）实验工况●Ultimate strength in aft direction●Ultimate strength in vertical direction●Accelerated fore/aft fatigue●Accelerated vertical fatigueThe applied loads for the accelerated fatigue tests were established based on analysis results & estimated fatigue life for the existing control arm to be within the range of 100,000 –200,000 cycles. The loads used for the accelerated fatigue tests were +/- 13,336 N for the fore/aft test and +40,009/0 N for the vertical test, respectively.载荷是通过球铰加上去的。
（2）控制臂前后方向的强度与疲劳计算的弯曲载荷为80，000N，铸造控制臂的弯曲载荷为87，000N，NRC 件的弯曲强度为109，375N。
前后方向的疲劳强度利用计算的应力结果和控制臂的破坏形式的对比（3）垂直方向的强度与水平方向的状况基本一致Optimizing Designs of Aluminum Suspension Components Using anIntegrated ApproachAlcoa Inc.(一种新的铝件加工工艺)In 1994, Alcoa leveraged its experience with high integrity aluminum castings from the aerospace business to quickly enter the aluminum chassis and suspension components market. In early 1995, Alcoa upgraded a proprietary casting process called Vacuum Riserless / Pressure Riserless Casting (VRC/PRC) and adapted it to the needs of the automotive chassis and suspension components market.VRC/PRC is a modified low-pressure, permanent mold casting process which uses vacuum and pressure to “bottom fill” a steel mold from a molten aluminum bath. VRC was developed in 1950’s by the Alcoa Casting & Forging Research Lab and was commercialized in the 1960’s. PRC was added to VRC in 1985 and the combined process is called VRC/PRC. The VRC/PRC casting machine consists of a vertical hydraulic press with a steel mold (upper and lower halves) that is bolted on to the machine’s lower platen.控制臂及其其中衬套的作用高性能的球头2003-01-3668 High Performance Ball Joint1. 研究对象：球头＋塑料球座（Ball joints constructed with plastic bearing）塑料球座的弹性、表面粗糙度和抗温度的特性。