Abstract

The application of composite materials is an important measure to reduce the automotive wheel’s weight. In order to ensure the safety of passengers, the wheels must pass a series of tests including the 13° impact test. For an injection-molded wheel, its production process has an influence on the material properties and residual stress distribution, which affect the wheel’s mechanical performance. In this paper, the residual stress is introduced to analyze its effect on the impact resistance of composite wheels made of long glass fiber reinforced thermoplastic. First, to obtain the material properties, the specimens are subjected to the tensile test. Based on the test data, the properties including failure parameters can be obtained by reverse engineering. Next, the in-cavity residual stress can be obtained by mold flow simulation, after simulating the relaxation of residual stress during demolding process, the residual stress is introduced to the 13° impact test model. Last, the simulation and corresponding tests with different impact velocities are carried out. The results illustrate that the fracture of the wheel can be accurately simulated by using the simulation method, and the residual stress generated by injection molding process has little effect on the response or damage of the wheel. Considering the calculation efficiency, it is unnecessary to introduce the residual stress when simulating the performance of composite wheel under 13° impact load. This method can also provide an effective reference for subsequent design and simulation for composite wheels.

摘要

复合材料的应用是减轻汽车车轮重量的重要措施。为了确保乘客的安全，车轮必须通过包括13°冲击试验在内的一系列测试。对于注塑成型的车轮，其生产工艺对材料性能和残余应力分布有影响，进而影响车轮的机械性能。本文引入残余应力，分析其对长玻璃纤维增​​强热塑性塑料复合材料车轮抗冲击性能的影响。首先，为了获得材料特性，对试样进行拉伸试验。基于测试数据，可以通过逆向工程获得包括失效参数在内的特性。接下来，可以通过模流模拟获得型腔内残余应力，在模拟脱模过程中残余应力的松弛后，将残余应力引入到13°冲击试验模型中。最后，进行了不同冲击速度下的仿真和相应的试验。结果表明，采用该模拟方法可以准确地模拟出车轮的断裂情况，注射成型过程中产生的残余应力对车轮的响应或损伤影响不大。考虑到计算效率，模拟复合轮在13°冲击载荷下的性能时，无需引入残余应力。该方法也可为后续复合材料轮毂的设计和仿真提供有效参考。残余应力被引入到 13° 冲击试验模型中。最后，进行了不同冲击速度下的仿真和相应的试验。结果表明，采用该模拟方法可以准确地模拟出车轮的断裂情况，注射成型过程中产生的残余应力对车轮的响应或损伤影响不大。考虑到计算效率，模拟复合轮在13°冲击载荷下的性能时，无需引入残余应力。该方法也可为后续复合材料轮毂的设计和仿真提供有效参考。残余应力被引入到 13° 冲击试验模型中。最后，进行了不同冲击速度下的仿真和相应的试验。结果表明，采用该模拟方法可以准确地模拟出车轮的断裂情况，注射成型过程中产生的残余应力对车轮的响应或损伤影响不大。考虑到计算效率，模拟复合轮在13°冲击载荷下的性能时，无需引入残余应力。该方法也可为后续复合材料轮毂的设计和仿真提供有效参考。结果表明，采用该模拟方法可以准确地模拟出车轮的断裂情况，注射成型过程中产生的残余应力对车轮的响应或损伤影响不大。考虑到计算效率，模拟复合轮在13°冲击载荷下的性能时，无需引入残余应力。该方法也可为后续复合材料轮毂的设计和仿真提供有效参考。结果表明，采用该模拟方法可以准确地模拟出车轮的断裂情况，注射成型过程中产生的残余应力对车轮的响应或损伤影响不大。考虑到计算效率，模拟复合轮在13°冲击载荷下的性能时，无需引入残余应力。该方法也可为后续复合材料轮毂的设计和仿真提供有效参考。