The Innovative Design of Suspension Cast Components of Vehicles Made from High-Strength AlZnMgCu Alloy Resistant to an IED Type Threat

Abstract:

The new research trends are moving away from research works that are not directly connected with industrial applications. The Integrated Computational Materials Engineering (ICME) is an excellent example of the relationship between scientific research and the industrial sector.As an example of the design development of construction of a suspension component, an overview of the changes of a welded part replaced with cast component is presented. The identification of boundary conditions and forces operating on the nodes of the suspension element allowed determining the critical areas in the existing welded construction. Then the new design of casting for high performance applications was developed. Analysis of the kinematics of the suspension components also revealed the need for changes in the design of the mounting points of the suspension components to reduce the maximum values ​​of forces and enforced moments. As a result of successive stages of the topology optimization of analysed cast, control arms with significantly lower values ​​of maximum stresses were obtained. The material conversion of welded part with high strength AlZnMgCu aluminium alloy allowed the reduction of the weight by 25% for the lower control arm and 30% for upper control arm.

• Periodical: Solid State Phenomena (Volume 223)
• Pages: 181-190
• DOI: https://doi.org/10.4028/www.scientific.net/SSP.223.181
• Online since: November 2014
• Authors: Robert Żuczek*, Stanisław Pysz, Piotr Sprawka, Tomasz Muszyński
• Keywords: Construction Conversion, High-Strength Aluminium Alloy, ICME Method, Material Conversion, Numerical Optimization, Simulation

References

[1] R. Żuczek, S. Pysz, A. Karwiński: Konwersja materiałowo-konstrukcyjna elementu kutego na odlewany. Prace Instytutu Odlewnictwa, tom 49, nr 3, 23-36, Kraków, (2009).

[2] R. Żuczek, S. Pysz, A. Karwiński, J. Piekło, P. Kowalski: Application of computers and rapid prototyping technique as an element of the cost-effective process of casting manufacture. Proceedings of 69 World Foundry Congress, pp.691-696, Chiny, Hangzou, October (2010).

[3] M.F. Horstemeyer: Integrated Coputational Materials Engineering (ICME) for Metals. Wiley, New Jersey, (2012).

[4] G.J. Schmitz, U. Prahl: Integrative Computational Materials Engineering. Wiley, Weinheim, (2012).

[5] S. Pysz, J. Piekło: Zastosowanie zintegrowanego systemu modelowania materiałów inżynierskich ICME w procesach odlewniczych. Prace Instytutu Odlewnictwa, Vol. LIII, nr 4, 57-70, Kraków, (2013).

[6] W. Barnat: Wybrane problemy energochłonności nowych typów paneli ochronnych obciążonych falą wybuchu, Bel Studio, Warszawa (2010).

[7] J. Wierciński: Wypadki drogowe - elementy analizy technicznej i opiniowania, WKiŁ Warszawa (1985).

[8] M.R. Rokni, A. Zarei-Hanzaki, Ali A. Roostaei, A. Abolhasani: Constitutive base analysis of a 7075 aluminum alloy during hot compression testing, Materials and Design 32 (2011) 4955–4960.

DOI: 10.1016/j.matdes.2011.05.040

[9] A. Zyska, Z. Konopka, M. Łagiewka, A. Bober, S. Nocuń: Modyfikacja stopu AlZn5Mg, Archive of Foundry, Vol. 6/22, Katowice, (2006).

[10] S. Rzadkosz, L. Staszczak: Kształtowanie struktury i właściwości wysokowytrzymałych stopów Al. -Zn-Mg, Solidification of Metals and Alloys, no. 36, Katowice (1998).

[11] N.J. Henry Holroyd, G.M. Scamans: Crack Propagation During Sustained-Load Cracking of Al-Zn-Mg-Cu Aluminum Alloys Exposed to Moist Air or Distilled Water, Metallurgical and Materials Transactions, Vol. 42a, December 2011, 3979–3998.

DOI: 10.1007/s11661-011-0793-x

[12] M. Maj, St. Pysz, J. Piekło, A. Gazda: Badania zmęczeniowe stopu AlZnMgCu przeznaczonego na elementy zawieszenia, Inżynieria Materiałowa, nr 6, Listopad-Grudzień (2012).

[13] St. Pysz, R. Żuczek, P. Sprawka, E. Czekaj, A. Karwiński, M. Małysza: Integration of numerical procedures in the design and manufacturing technology on the example of a cast component for the automotive industry, 70th World Foundry Congress 2012, Monterrey, Mexico; 04/(2012).

[14] R. Żuczek, S. Pysz: The use of ICME process to design a rocker arm for special purpose vehicles. TEKA - An International Journal on Motorization, Vehicle Operation Energy Efficiency and Mechanical Engineering, pp.205-211. Vol. 12/1, (2012).