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Fatigue and impact analysis and multi-objective optimization design of Mg/Al assembled wheel considering riveting residual stress

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Abstract

The multi-material assembled light alloy wheel presents an effective lightweight solution for new energy vehicles, but its riveting connection remains a problem. To address this problem, this paper proposed the explicit riveting-implicit springback-implicit fatigue/explicit impact sequence coupling simulation analysis method, analyzed the fatigue and impact performance of the punching riveting connected magnesium/aluminum alloy (Mg/Al) assembled wheel, and constructed some major evaluation indicators. The accuracy of the proposed simulation method was verified by conducting physical experiments of single and cross lap joints. The punching riveting process parameters of the assembled wheel joints were defined as design variables, and the fatigue and impact performance of the assembled wheel was defined as the optimization objective. The connection-performance integration multi-objective optimization design of the assembled wheel considering riveting residual stress was designed via Taguchi experiment, grey relational analysis, analytic hierarchy process, principal component analysis, and entropy weighting methods. The optimization results of the three weighting methods were compared, and the optimal combination of design variables was determined. The fatigue and impact performance of the Mg/Al assembled wheel were effectively improved after optimization.

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Abbreviations

AHP:

Analytic hierarchy process

BCSLIB-EXT:

Boeing’s Extreme Mathematical Library

BFGS:

Broyden-Fletcher-Goldfarb-Shanno

DOE:

Design of experiment

DOF:

Degree of freedom

FE:

Finite element

GRA:

Grey relational analysis

GRG:

Grey relational grade

Mg/Al:

Magnesium/aluminum alloy

PCA:

Principal component analysis

S/R:

Selectively reduced

B :

Comparison judgment matrix

E r(x):

Energy absorption of the rim under the 90° impact condition

SC R-bend(x), SC R-radial(x):

Maximum bending and radial compressive stresses at the rivet, respectively

SC s-bend(x), SC s-radial(x):

Maximum bending and radial compressive stresses at the spoke riveting hole, respectively

ST R-bend(x), ST R-radia(x):

Maximum bending and radial tensile stresses at the rivet, respectively

ST s-bend(x), ST s-radial(x):

Maximum bending and radial tensile stresses at the spoke riveting hole, respectively

S 13-s(x):

Maximum von Mises strain of the spoke under the 13° impact condition

W c, W t :

Weight coefficients of the maximum compressive and tensile stresses, respectively

x 1, x 2 :

Groove diameter and height of the upper riveting die, respectively

x 3 :

Riveting displacement factor

x 4 :

Extension of the rivet rod

x :

Vector of design variables

x L :

Lower limits of the vector x

x U :

Upper limits of the vector x

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Acknowledgements

This work was supported by the National Natural Science Foundation of China (Grant Nos. 51975244 and 51475201). The authors would like to express their appreciations for the fund supports.

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Authors and Affiliations

  1. State Key Laboratory of Automotive Simulation and Control, Jilin University, Changchun, 130022, China

    Wenchao Xu & Dengfeng Wang

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  1. Wenchao Xu
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Correspondence to Dengfeng Wang.

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The authors declared no potential conflicts of interest with respect to the research, authorship, and/or publication of this article.

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Xu, W., Wang, D. Fatigue and impact analysis and multi-objective optimization design of Mg/Al assembled wheel considering riveting residual stress. Front. Mech. Eng. 17, 45 (2022). https://doi.org/10.1007/s11465-022-0701-7

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