The multi-material assembled light alloy wheel presents an effective lightweight solution for new energy vehicles, but its riveting connection remains a problem. To address this problem, this paper proposed the explicit riveting-implicit springback-implicit fatigue/explicit impact sequence coupling simulation analysis method, analyzed the fatigue and impact performance of the punching riveting connected magnesium/aluminum alloy (Mg/Al) assembled wheel, and constructed some major evaluation indicators. The accuracy of the proposed simulation method was verified by conducting physical experiments of single and cross lap joints. The punching riveting process parameters of the assembled wheel joints were defined as design variables, and the fatigue and impact performance of the assembled wheel was defined as the optimization objective. The connection-performance integration multi-objective optimization design of the assembled wheel considering riveting residual stress was designed via Taguchi experiment, grey relational analysis, analytic hierarchy process, principal component analysis, and entropy weighting methods. The optimization results of the three weighting methods were compared, and the optimal combination of design variables was determined. The fatigue and impact performance of the Mg/Al assembled wheel were effectively improved after optimization.
Energy absorption of the rim under the 90° impact condition
SCR-bend(x), SCR-radial(x)
Maximum bending and radial compressive stresses at the rivet, respectively
SCs-bend(x), SCs-radial(x)
Maximum bending and radial compressive stresses at the spoke riveting hole, respectively
STR-bend(x), STR-radia(x)
Maximum bending and radial tensile stresses at the rivet, respectively
STs-bend(x), STs-radial(x)
Maximum bending and radial tensile stresses at the spoke riveting hole, respectively
S13-s(x)
Maximum von Mises strain of the spoke under the 13° impact condition
Wc, Wt
Weight coefficients of the maximum compressive and tensile stresses, respectively
x1, x2
Groove diameter and height of the upper riveting die, respectively
x3
Riveting displacement factor
x4
Extension of the rivet rod
x
Vector of design variables
xL
Lower limits of the vector x
xU
Upper limits of the vector x
Group
x1/mm
x2/mm
x3
x4/mm
1
8.70
2.50
0.80
6.00
2
8.70
2.70
0.83
6.40
3
8.70
2.90
0.86
6.80
4
9.00
2.50
0.83
6.80
5
9.00
2.70
0.86
6.00
6
9.00
2.90
0.80
6.40
7
9.30
2.50
0.86
6.40
8
9.30
2.70
0.80
6.80
9
9.30
2.90
0.83
6.00
Group
STs-bend/MPa
SCs-bend/MPa
STR-bend/MPa
SCR-bend/MPa
STs-radial/MPa
SCs-radial/MPa
STR-radial/MPa
SCR-radial/MPa
S13-s/MPa
Er/J
1
317.8
660.8
485.0
508.6
306.7
655.6
485.0
508.6
0.1339
707.36
2
377.5
716.5
529.4
519.2
398.5
712.4
529.4
519.2
0.1342
715.41
3
408.8
807.6
548.9
515.6
409.7
812.5
548.9
515.6
0.1302
710.30
4
380.7
790.8
564.6
523.0
387.0
790.0
564.6
523.0
0.1311
703.55
5
392.4
668.9
499.6
507.9
388.6
653.4
499.5
507.9
0.1324
709.43
6
297.3
608.0
436.4
343.8
293.4
601.3
436.4
343.8
0.1378
714.95
7
328.6
728.3
488.8
511.1
319.3
742.4
488.8
511.1
0.1313
717.09
8
309.4
632.7
481.2
473.0
305.4
636.0
481.8
473.0
0.1337
705.94
9
334.8
587.8
441.0
357.7
336.6
594.7
441.0
357.7
0.1407
701.49
Group
GRC
STs-bend
SCs-bend
STR-bend
SCR-bend
STs-radial
SCs-radial
STR-radial
SCR-radial
S13-s
Er
Reference experiment
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1
0.731
0.428
0.569
0.862
0.814
0.410
0.569
0.862
0.587
0.571
2
0.410
0.547
0.408
0.959
0.356
0.521
0.408
0.959
0.568
0.359
3
0.333
1.000
0.363
0.924
0.333
1.000
0.363
0.924
1.000
0.470
4
0.401
0.867
0.333
1.000
0.383
0.829
0.333
1.000
0.854
0.791
5
0.370
0.442
0.504
0.856
0.379
0.406
0.504
0.856
0.705
0.496
6
1.000
0.355
1.000
0.333
1.000
0.340
1.000
0.333
0.409
0.367
7
0.640
0.581
0.550
0.883
0.692
0.608
0.550
0.883
0.827
0.333
8
0.822
0.386
0.589
0.642
0.829
0.382
0.585
0.642
0.600
0.637
9
0.598
0.333
0.933
0.352
0.574
0.333
0.933
0.352
0.333
1.000
Wt/Wp
Weight
STs-bend
SCs-bend
STR-bend
SCR-bend
STs-radial
SCs-radial
STR-radial
SCR-radial
S13-s
Er
0.9:0.1
0.2139
0.0238
0.2139
0.0238
0.1748
0.0194
0.1748
0.0194
0.0823
0.0538
0.8:0.2
0.1902
0.0475
0.1902
0.0475
0.1554
0.0388
0.1554
0.0388
0.0823
0.0538
0.7:0.3
0.1664
0.0713
0.1664
0.0713
0.1360
0.0583
0.1360
0.0583
0.0823
0.0538
0.6:0.4
0.1426
0.0951
0.1426
0.0951
0.1165
0.0777
0.1165
0.0777
0.0823
0.0538
0.5:0.5
0.1188
0.1188
0.1188
0.1188
0.0971
0.0971
0.0971
0.0971
0.0823
0.0538
Group
GRG
En
PCA
AHP-0.9:0.1
AHP-0.8:0.2
AHP-0.7:0.3
AHP-0.6:0.4
AHP-0.5:0.5
Reference experiment
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1
0.595
0.647
0.654
0.652
0.649
0.647
0.645
2
0.560
0.580
0.439
0.470
0.500
0.530
0.560
3
0.761
0.695
0.461
0.514
0.567
0.620
0.673
4
0.727
0.671
0.475
0.524
0.572
0.621
0.669
5
0.532
0.571
0.481
0.499
0.516
0.534
0.551
6
0.545
0.637
0.860
0.803
0.746
0.690
0.633
7
0.653
0.690
0.622
0.633
0.644
0.656
0.667
8
0.557
0.604
0.677
0.660
0.644
0.627
0.610
9
0.504
0.541
0.702
0.666
0.630
0.594
0.557
Objectives
STs-bend/MPa
SCs-bend/MPa
STR-bend/MPa
SCR-bend/MPa
STs-radial/MPa
SCs-radial/MPa
STR-radial/MPa
SCR-radial/MPa
S13-s/MPa
Er/J
Before optimization
425.9
1016.5
508.8
531.6
434.2
979.9
507.3
531.6
0.1368
725.06
Optimal scheme I
377.7
789.4
564.1
528.0
391.4
788.2
564.1
520.8
0.1306
705.55
Optimal scheme II
283.5
619.9
457.5
474.5
280.1
631.4
457.5
474.5
0.1335
706.67
Optimal scheme III
293.9
588.8
436.3
352.1
292.3
575.6
436.3
352.1
0.1199
719.08
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