重卡铝合金轻量化

Total : 46 kg
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Truck Chassis/Frame – Forged Aluminum 5th Wheel
Weight Save vs. the Competition
Bracket Style Stationary Mount 24” Travel Slider Bracket Style Stationary Mount 24” Travel Slider Alcoa/Holland FW (kg) 90 174 Competitor A (kg) 145 231 Weight Save (kg) 55 57
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美铝重卡铝合金底盘成功案例
Daimler DOE Supertruck chassห้องสมุดไป่ตู้s
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重卡底盘主梁
典型的重卡钢制主梁Typical steel rails of HDT

高度 300 mm， 法兰边宽度 90 mm，厚度 7 mm 大约重量 198 kg/根


Typical steel rails of HDT
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基本工艺-折弯、打孔
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美铝铝合金副梁的成功案例
Aluminum Cross Members for Class 8 trucks
Volvo NA offers 2 different aluminum cross members as customer options Volvo 北美分公司为客户提供2种不同的铝合金副梁的选择 Kenworth and Peterbilt use 2 aluminum cross members as standard on their chassis Kenworth和Peterbilt采用2个铝合金副梁作为底盘的标准配置
300 mm high, 90 mm wide flanges and 7 mm thick
Weight = 198 kg/each
替换方案：在不改变现有的生产线的基础上，采
用高强度的铝合金，滚压成形加自动化钻孔

等效的铝合金主梁尺寸：330 mm x 100 mm x 9.5
mm
Proposed aluminum rails made of a high strength Al alloy using the same production facility as the current steel rails – roll formed, and automatic punched holes


Equivalent Aluminum Frame rails are 330 mm x 100 mm x 9.5 mm thick
Weight Savings = 190 kg per truck
节约的重量最高可达：190 kg
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基本工艺-滚压
Aluminum Frame Rails Produced at Metalsa
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某副梁的减重设计
8.27 kg
3.33 kg
2.46 kg
Total Weight: 19.85 kg
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某副梁的设计分析
“Tie Plate” vertical wall = 9 mm thick Cross-member = 11mm thick
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某副梁减重效果
Weight (kg)
Existing Steel Cross Member 现有钢制副梁设计 Proposed Aluminum Cross member 铝合金副梁设计 34
Frame Rails 200 KG
Bonnet 80 KG Radiator Shutters 7 KG Bumpers 15 KG
Suspension 110 KG
Engine Parts 50 KG
Transmission Housing 75 KG
Wheels 200 KG
Fuel Tanks 25 KG
Alcoa/Holland FW (kg)
90 174
Competitor B (kg)
141 221
Weight Save (kg)
51 47
Forged 6061-T6 Aluminum Load Capacity: 25 ton Max. Vertical Weight Save: up to 57 kg
重型卡车轻量化技术交流 Technical Discussion for HDT Lightweight Design
2014/11/4
重型卡车可采用铝合金减重的方向（1137kg）
Cab 200 KG
Cab Doors 15 KG
Body Trim 10 KG
Cross members 150 KG
Weight Savings
19.85
14.15 kg (42 %)
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各个副梁的可能减重机会
Weight savings potential by converting all truck cross members to aluminum:
（如果以铝代替钢，各个部分的副梁的减重效果） ‒ Taper rear cross 2 kg ‒ Bogie 16 kg ‒ Front of bogie 7 kg ‒ Intermediate 7 kg ‒ After transmission 6 kg ‒ Over transmission 3 kg ‒ Front Closing 5 kg