Topology Optimization and Lightweight Platform Development of Pure Electric Vehicle Frame-Type Aluminum Body Considering Crash Performance

Unlike traditional steel body transfer paths and part design, framed Al body tooling has less investment and shorter development cycles. Research on the framed Al body structure and topology optimization has led to the creation of an innovative development platform for pure electric vehicles of different sizes and ranges. First, based on the forward design, the comprehensive working conditions are incorporated into the topology optimization analysis to derive the optimal force transfer path. Subsequently, the longitudinal beam and subframe lap are optimized for the frontal collision risk term to effectively absorb collision energy and control deformation. The acceleration on the left side of the B-pillar decreases by 4.4 g, the acceleration on the right side improves by 3.12 g, and the front wall panel intrusion is reduced by 38 mm, which provides a well-matched condition for the occupant restraint system. Finally, based on the pure electric sedan as a template, an innovative framed Al body lightweight platform is developed to accommodate models of different sizes and ranges, resulting in a 67.3% versatility rate under 2-passenger and 4-passenger seats. The research is a forward-looking guide to the integrated design and application technology of various lightweight components on the whole vehicle.