针对某乘用车钢制前端框架和技术性能要求,通过长纤维增强热塑性复合材料(LFT)机械性能对比分析,结合LFT前端框架生产工艺和制造成本,确定选用PP-LGF30粒料进行LFT前端框架开发。通过汽车前端框架集成设计,对多目标优化设计后的结构,进行了模流分析,确定了最终设计方案。基于零件3D图,开发了模具,应用注塑成形的方法试制了LFT前端框架,对试制件进行了多项台架测试和整车匹配验证。结果表明:各项指标达到使用要求,LFT前端框架相比传统钢制件,减重比例达到56%,取得了良好的轻量化效果。

According to the requirements of steel front-end module and technical performance of passenger car,through the comparative analysis of mechanical properties of long fiber reinforced thermoplastics(LFT) material,combined with the production process and manufacturing cost of LFT front-end module,PP-LGF30 granular material was selected for the development of LFT front-end module.Through the integrated design of automobile front-end module,the multi-objective optimized structure was analyzed by the mode flow analysis,and the final design scheme was determined.Based on the 3D drawing of parts,the die was developed,and the LFT front-end module was trial-produced by injection moulding method.A number of bench tests and vehicle matching validation were carried out.The test results shown that all the indexes met the requirements.Compared with the traditional steel parts,the weight reduction ratio of LFT front-end module reached 56%,and achieved good lightweight effect.