Lightweighting of a Recreational Vehicle Frame Structure using Advanced High Strength Materials and Joining Processes

欧文海默集团北美公司(EHGNA)是B级房车和拖车的主要制造商，在安大略省剑桥市设有生产工厂。为了扩大他们的市场，显然有必要减轻车辆的重量，以便更多的乘用车能够拖曳拖车。为了实现这一目标，现有结构的重量必须从**大约2600磅减少到2000磅。要达到这一目标，将需要高强度的轻金属，这不可避免地会导致制造过程的**复杂。从装配和使用性能的角度来看，选择和优化不同材料的连接工艺对于确保新车架设计的可行性至关重要。目前的**工作将研究框架结构的轻量化，重点是轻金属，包括高强度6xxx系列**铝挤压件和带有新型泡沫铝芯材的夹层结构。将生成泡沫和挤压的数值模型**，并用于重新设计机架和实现部件固结。重点是**开发适当的泡沫铝与钢和铝的连接方法，以及**玻璃纤维外壳与框架的连接。

Erwin Hymer Group North America (EHGNA) is a major manufacturer of Class B motor homes and trailers with a production**facility in Cambridge, Ontario. To increase their market, there is a clear need to reduce vehicle weight so that a larger range of**passenger vehicles can tow the trailers. To achieve this goal, the weight of the existing structure must be reduced from**approximately 2600 lbs, to 2000 lbs. High strength light metals will be required to reach this target which inevitably leads to**complications in the manufacturing process. The selection and optimization of the joining processes of dissimilar materials is**critical to ensure that the new frame design is feasible from the perspective of assembly and in-service performance. The present**work will investigate lightweighting of the frame structure with an emphasis upon light metals including high strength 6xxx-series**aluminium extrusions and sandwich structures with a novel aluminium foam core. Numerical models of the foam and extrusions**will be generated and used to re-design the frame and achieve part consolidation. An emphasis will be placed upon the**development of the appropriate joining methodology for the aluminium foam to steel and aluminium as well as joining of the**fiberglass shell to the frame