Abstract
Aiming at the need for lightweight requirements of the electric bus components, combined with the performance advantages of the hot stamping ultra-high strength steel, a new type of seat bracket structure is proposed. The new structure was analyzed by finite element method and the variable density topology optimization results. Subsequently, the new seat bracket was manufactured by the indirect hot stamping process. The results showed that the new type of seat bracket can reduce the weight by 17.04% after topology optimization, which achieved the goal of lightweight design of the structure. After indirect hot stamping, the bottom of the seat bracket microstructures were mainly martensite and the ultimate tensile strength was about 1560 MPa, the microhardness was equally distributed at about 513.5 HV. Finally, according to the stiffness check test, the seat bracket satisfied the user requirements.
Highlights
The electric bus is becoming more practical today because of its lower pollution and less noise with higher energy efficiency compared to the fuel bus [1,2]
Many finite element method (FEM) commercial software have the structural optimization module, e.g. the SIMULIA Tosca Structure applied in ABAQUS, ANSYS [3]
This paper focused on using ultra-high strength steel on electric bus components
Summary
The electric bus is becoming more practical today because of its lower pollution and less noise with higher energy efficiency compared to the fuel bus [1,2]. High stiffness is a requirement for most automobile components (e.g. brackets, car body) in simulation In this situation, using finite element analysis (FEA) is a more convenient and reasonable way to optimize the structure. Seo et al investigated the formability of direct and indirect hot stamping processes under different blank holding forces of ultra-high strength steel [17]. This kind of material is rarely used on the electric bus. This paper focused on redesigning the new structure of the seat bracket according to the finite element analysis and topology optimization method. To verify the rationality of the design, stiffness experiment was performed on the seat bracket
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