Mechanical properties analysis of PP-LGF40 and DC01 automotive front-end frames based on lightweight technology

In this paper, a front-end frame of a new energy vehicle is designed, and the CATIA model is established by combining the relevant parameters of the target material, and the mechanical properties of different materials under different working conditions are analyzed in depth by using ANSYS workbench software. Through parametric design, geometric modeling, material properties, and boundary conditions, the mechanical properties of all-metal, all-plastic, and mixed plastic and steel front-end frames were simulated for comparative analysis and research. In the simulation process, the static mechanical performance of the front-end frame is analyzed using the parameter indexes under different working conditions. The study shows that PP-LGF40 material has insufficient stiffness but very light mass, according to the observed stress maximum point and deformation maximum location in the vicinity of the hood main lock and upper frame, the combination of steel DC01 + PP-LGF40 is finally adopted, the main lock and upper frame part with the largest deformation is made of steel DC01 material, while the lower frame part with smaller deformation is made of lighter PP-LGF40 material. The mass of the optimized front-end frame is 5.1201 kg, which is 35.52% lighter than the steel DC01 front-end frame of 7.9417 kg, and the lightweight effect is obvious. After ANSYS analysis and calculation of the main lock of the front-end frame in 2500 N load, the maximum compressive force can be 523.38 MPa, and the maximum deformation of the main lock is 1.3552 mm.The model of the automobile front-end frame made of a mixture of plastic and steel materials uses steel in the area of the larger force, and uses plastic in the other areas, which can not only ensure the mechanical properties of the requirements, but also achieve the requirements of lightweight.