汽车车身气动造型设计优化研究
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摘要
车身造型设计是汽车整车开发中极为重要的一环,而决定车身造型设计的关键在于工业设计所代表的美学造型和空气动力学所代表的气动造型。工业设计需要考虑车身外观美感、品牌继承性、用户体验心理等视觉方面的内容,而空气动力学则涉及车身的减阻降噪及高速气动稳定性等方面的内容,两者在思维方式和设计方法上截然不同,如何实现两者的结合以设计出既具有美观造型又具有优良气动性能的车身是一个富有挑战的学科交叉问题。
除了正向开发中的气动造型设计外,对完成度较高的既有车型进行气动优化也是气动造型研究运用的重点,目前主流的细部迭代优化法需要对局部进行大量尝试性修改,盲目性较大且效率低；在工程领域常用的诸如遗传算法等优化方法只适合形状较为简单、可参数量化的规则形体,尚无法直接用于形状复杂且包含大量自由曲面的整车车身模型,所以需要一种针对复杂既有车型的气动造型优化方法。
从汽车领域的空气动力学研究手段来看,除了高成本的风洞实验外,运用最广泛的当属CFD (Computer Fluid Dynamics)流体计算仿真技术。经过多年的发展CFD技术已较为成熟,目前的研究发展集中在诸如湍流方程、网格划分等环节,考虑到CFD仿真是一个综合性的处理过程,可以从模型前处理环节来提高优化设计的效率和精度。
因此加强气动造型设计与工业设计的结合,改进气动造型优化方法,提高CFD仿真优化的精度和效率,都将提高车身造型的气动设计水平,而气动性能与动力性、燃油经济性、高速行驶稳定性等性能是密切相关的,高水平的气动造型设计将全面提升整个车辆的研发设计水准。
本文以提高车身气动造型水平为出发点,从设计方法和设计手段上进行了研究和探索。对气动造型设计方法的研究分为两条方向：在正向设计中实现气动造型与美学造型的融合、在后期改型中提高气动造型优化的效率和质量；对设计手段的研究集中在CFD优化仿真上,因为气动设计方法如果没有先进的仿真优化手段作为支撑其效果将大打折扣,本文从车身曲面CAD模型与CFD之间的集成入手,对提高仿真优化的效率和精度进行了研究。
本文所采用的关键技术：
1.车身正向设计中气动造型与美学造型的融合交互
在车身造型的前期设计中,如果引入优良气动性能的理想形体作为设计起点,那对于后期的气动造型设计将起到事半功倍的作用。但这样需要在气动理想形体上进行美学造型设计和实用化设计,不符合汽车工业造型设计的传统流程和思维习惯,因此需要建立一套结合气动造型基因和美学造型基因的融合交互机制。它所涉及的关键技术为：
1)建立造型基因的图形学描述机制。研究气动造型基因、美学造型基因的构建方式及定义标准,建立基于车身数字设计平台下的造型基因描述方法和数学模型,该模型具有标准规范的图形学描述语言,能够满足可互换、可进化的设计要求。
2)建立上述两类造型基因在设计进化中的融合交互机制。研究在车身造型的进化成型中,气动造型基因和美学造型基因的交互、调谐与融合,包括同一平面下的同向融合和三维空间下的异向融合。
2.优化完成度较高的既有车型的整体气动布局
很多情况下出于减少模具和重新设计的需要,汽车企业需要对既有车型进行有限度的改型以优化气动性能；在传统正向设计中直接由工业设计师所构建出的造型方案,也需要进行气动优化。传统的细部迭代优化需要进行大量的修改尝试和仿真验证,存在盲目性大、效率低的问题,而且改型方案之间也可能存在效果冲突。对此现状本文提出一种针对完成度较高车型的整体气动布局优化设计理论,它所涉及的关键技术为：
1)对非气动细节的过滤技术。实际车型包含大量为功能实用而添加的非气动细节,它们对整车流场的影响有限,但其存在使得仿真优化的效率大为下降,不利于发现整体气动布局的设计缺陷。可以将这类细节过滤,对析取出的气动基本造型进行分析优化。
2)变形盒技术。这是一种基于控制点拉伸形变的模型修改技术,适合包含自由曲面的车身覆盖件,能够灵活的修改曲面的变化趋势,也可以同时对多个局部进行修改,避免了细部迭代优化法的局限性,有利于整体气动布局的改善。
3.改进CFD仿真优化的效率和质量
CFD仿真是车身气动造型设计的重要研究手段,本文从几何模型与计算网格划分的角度出发,提出一种适合车身曲面造型的模型构建技术,它能够大幅提高造型优化的效率和自由度,并在CFD计算网格的划分中保证较好的模拟精度。它所涉及的关键技术为：
1)细分网格技术。在车身设计中传统的nurbs曲面具有精度高、光顺性好的优点,但由于采用了面片连续性拼接而导致模型数据结构复杂,在进行计算网格划分和优化改型时存在收敛性差、效率低、自由度不高的缺点,通过采用新型的细分网格模型替代nurbs模型,能够在保证仿真精度的前提下提高优化设计的效率和质量。
2)计算网格几何特征处理技术。在CFD计算网格的划分中,为了提高仿真精度需要保证计算网格能够高精度的模拟几何模型,通过对细分网格模型进行几何特征处理以改善划分网格的贴体性,使计算节点能够准确捕捉车身造型的几何信息。
The style design is an important process in vehicle design project, the key factor is aesthetics from industry design and aerodynamics from engineering.In industry design the stylists need to take into account the body shape aesthetic feeling,company brand,customer experience,etc,but the aerodynamics concern how to reduce the resistance force and the noise and the stability in high speed driving,the two side is different in thinking habit and design method, how to integrate them so the final vehicle is perfect in styling and aerodynamics is an challenging problem.
Except for the forward design,optimizing the existent vehicle aerodynamics performance is another research point, current minor iterative optimizing method need to modify the local part trial and error,is an blindfold and low efficiency method;The main optimizing method in engineering field such as inherit arithmetic is appropriate for the inerratic object which is simple and can be parameterized,it is not suitable for the vehicle model which is complex and include a mass of free-form surface,so an aerodynamics optimizing method specialized for automobile is necessary.
For aerodynamics research technique,except high cost wind tunnel test,CFD(Computer Fluid Dynamics) is another popular way.After thirty years development it is an almost advanced technique, currently such as turbulence model and mesh subdividsion is most concerned,because CFD is an all-around process,it is possible to improve the efficiency and precision from model aspect.
So enhancing the integration between aerodynamics and industry design,improving model optimizing technique,increasing the efficiency and precision of CFD simulation,are necessary for automobile style design and aerodynamics design,and the vehicle aerodynamics performance is correlative with dynamic performance,fuel consumption and high speed stability.Good aerodynamics design is important for entire vehicle developing project.
The target of this paper is to improve vehicle aerodynamics condition,made research and explore in design method and design technique.In design method aspects,two different direction was discussed:how to integrate aerodynamics and aesthetics in forward design,how to improve efficiency and quality in later stage optimization;In design technique aspects,the research focus on CFD simulation and optimization,because witout advanced CFD technique any design method cannot get good result,so the exchange between CAD model and CFD was researched.
The key technology:
1. The integration mechanism between aerodynamics and aesthetics in vehicle body forward design
In the process of vehicle body forward design,if a ideal model is chosen as start point which is perfect in aerodynamics performance,it is a great help for next design process.But it need to sculp and modify on the smooth ideal shape,and this work flow is not accord with traditional habit, so it is necessary to constitute a integration mechanism between aerodynamics and aesthetics.The correlative key technique is:
1) Build up the describing mechanism for style gene.Research the describing mode and definition standard for aerodynamics gene and style gene,establish corresponding describing measure and mathematics model based on bodywork design platform,this model can fulfil the request on exchange and evolution for model describing in CAD platform.
2) Establish integration mechanism in design process.Research how to integrate and syncretize for aerodynamics gene and style gene,include2D integrating and3D integrating.
2. Optimizing holistic aerodynamics layout for finished vehicle
For reducing cost in redesign, the automobile company need to modify the vehicle limited to improve aerodynamics performance; the style project deigned by stylists also need to be optimized.Traditional minor iterative optimizing method need to modify the local part trial and error,is an blindfold and low efficiency method.So a new kind of optimizing method aimed to finished vehicle is necessary.The correlative key technique is:
1) Filtration for non-aerodynamics parts.The actual vehicle include a great deal of non-aerodynamics parts which have limited influence to holistic flow field,but it greatly decrease the efficiency in CFD simulation and optimizing and it is difficult to find out the disfigurement in aerodynamics layout.So it is feasible to filtrate these parts and optimize the basic shape.
2) Distortion technique.It is a modify technique based on control box,it suits the freeform surface in vehicle bodywork and can freely modify the shape,avoids the limitation in minor iterative optimizing method.
3. Improve the efficiency and quality in CFD simulation and optimizing
CFD simulation is a verv important measure in automobile stvle design,from the viewpoint of CAD model and calculating mesh,a new kind of model technology fit for bodywork surface is brought out,it can greatly improve the efficiency in model optimizing and maintenance good precision in CFD simulation.The correlative key technique is:
1) Subdivision mesh technology.In vehice deign progress the traditional nurbs surface have the advantage of high precision and good smoothness,but the model hiberarchy is complicated because the surface is made up of patches,it has the disadvantage of low efficiency and freeness in mesh subdiving process,by introducing new subdivision mesh model instead of nurbs model,the efficiency and quality in CFD simulation can be improved and the precision can keep in acceptable level.
2) The features for calculating mesh.In mesh generating process,in order to improve simulation precision it is feasible to make feature work on mesh object so the calculating mesh is more close to original model and the nodes can snap to geometry information on bodywork.
除了正向开发中的气动造型设计外,对完成度较高的既有车型进行气动优化也是气动造型研究运用的重点,目前主流的细部迭代优化法需要对局部进行大量尝试性修改,盲目性较大且效率低；在工程领域常用的诸如遗传算法等优化方法只适合形状较为简单、可参数量化的规则形体,尚无法直接用于形状复杂且包含大量自由曲面的整车车身模型,所以需要一种针对复杂既有车型的气动造型优化方法。
从汽车领域的空气动力学研究手段来看,除了高成本的风洞实验外,运用最广泛的当属CFD (Computer Fluid Dynamics)流体计算仿真技术。经过多年的发展CFD技术已较为成熟,目前的研究发展集中在诸如湍流方程、网格划分等环节,考虑到CFD仿真是一个综合性的处理过程,可以从模型前处理环节来提高优化设计的效率和精度。
因此加强气动造型设计与工业设计的结合,改进气动造型优化方法,提高CFD仿真优化的精度和效率,都将提高车身造型的气动设计水平,而气动性能与动力性、燃油经济性、高速行驶稳定性等性能是密切相关的,高水平的气动造型设计将全面提升整个车辆的研发设计水准。
本文以提高车身气动造型水平为出发点,从设计方法和设计手段上进行了研究和探索。对气动造型设计方法的研究分为两条方向：在正向设计中实现气动造型与美学造型的融合、在后期改型中提高气动造型优化的效率和质量；对设计手段的研究集中在CFD优化仿真上,因为气动设计方法如果没有先进的仿真优化手段作为支撑其效果将大打折扣,本文从车身曲面CAD模型与CFD之间的集成入手,对提高仿真优化的效率和精度进行了研究。
本文所采用的关键技术：
1.车身正向设计中气动造型与美学造型的融合交互
在车身造型的前期设计中,如果引入优良气动性能的理想形体作为设计起点,那对于后期的气动造型设计将起到事半功倍的作用。但这样需要在气动理想形体上进行美学造型设计和实用化设计,不符合汽车工业造型设计的传统流程和思维习惯,因此需要建立一套结合气动造型基因和美学造型基因的融合交互机制。它所涉及的关键技术为：
1)建立造型基因的图形学描述机制。研究气动造型基因、美学造型基因的构建方式及定义标准,建立基于车身数字设计平台下的造型基因描述方法和数学模型,该模型具有标准规范的图形学描述语言,能够满足可互换、可进化的设计要求。
2)建立上述两类造型基因在设计进化中的融合交互机制。研究在车身造型的进化成型中,气动造型基因和美学造型基因的交互、调谐与融合,包括同一平面下的同向融合和三维空间下的异向融合。
2.优化完成度较高的既有车型的整体气动布局
很多情况下出于减少模具和重新设计的需要,汽车企业需要对既有车型进行有限度的改型以优化气动性能；在传统正向设计中直接由工业设计师所构建出的造型方案,也需要进行气动优化。传统的细部迭代优化需要进行大量的修改尝试和仿真验证,存在盲目性大、效率低的问题,而且改型方案之间也可能存在效果冲突。对此现状本文提出一种针对完成度较高车型的整体气动布局优化设计理论,它所涉及的关键技术为：
1)对非气动细节的过滤技术。实际车型包含大量为功能实用而添加的非气动细节,它们对整车流场的影响有限,但其存在使得仿真优化的效率大为下降,不利于发现整体气动布局的设计缺陷。可以将这类细节过滤,对析取出的气动基本造型进行分析优化。
2)变形盒技术。这是一种基于控制点拉伸形变的模型修改技术,适合包含自由曲面的车身覆盖件,能够灵活的修改曲面的变化趋势,也可以同时对多个局部进行修改,避免了细部迭代优化法的局限性,有利于整体气动布局的改善。
3.改进CFD仿真优化的效率和质量
CFD仿真是车身气动造型设计的重要研究手段,本文从几何模型与计算网格划分的角度出发,提出一种适合车身曲面造型的模型构建技术,它能够大幅提高造型优化的效率和自由度,并在CFD计算网格的划分中保证较好的模拟精度。它所涉及的关键技术为：
1)细分网格技术。在车身设计中传统的nurbs曲面具有精度高、光顺性好的优点,但由于采用了面片连续性拼接而导致模型数据结构复杂,在进行计算网格划分和优化改型时存在收敛性差、效率低、自由度不高的缺点,通过采用新型的细分网格模型替代nurbs模型,能够在保证仿真精度的前提下提高优化设计的效率和质量。
2)计算网格几何特征处理技术。在CFD计算网格的划分中,为了提高仿真精度需要保证计算网格能够高精度的模拟几何模型,通过对细分网格模型进行几何特征处理以改善划分网格的贴体性,使计算节点能够准确捕捉车身造型的几何信息。
The style design is an important process in vehicle design project, the key factor is aesthetics from industry design and aerodynamics from engineering.In industry design the stylists need to take into account the body shape aesthetic feeling,company brand,customer experience,etc,but the aerodynamics concern how to reduce the resistance force and the noise and the stability in high speed driving,the two side is different in thinking habit and design method, how to integrate them so the final vehicle is perfect in styling and aerodynamics is an challenging problem.
Except for the forward design,optimizing the existent vehicle aerodynamics performance is another research point, current minor iterative optimizing method need to modify the local part trial and error,is an blindfold and low efficiency method;The main optimizing method in engineering field such as inherit arithmetic is appropriate for the inerratic object which is simple and can be parameterized,it is not suitable for the vehicle model which is complex and include a mass of free-form surface,so an aerodynamics optimizing method specialized for automobile is necessary.
For aerodynamics research technique,except high cost wind tunnel test,CFD(Computer Fluid Dynamics) is another popular way.After thirty years development it is an almost advanced technique, currently such as turbulence model and mesh subdividsion is most concerned,because CFD is an all-around process,it is possible to improve the efficiency and precision from model aspect.
So enhancing the integration between aerodynamics and industry design,improving model optimizing technique,increasing the efficiency and precision of CFD simulation,are necessary for automobile style design and aerodynamics design,and the vehicle aerodynamics performance is correlative with dynamic performance,fuel consumption and high speed stability.Good aerodynamics design is important for entire vehicle developing project.
The target of this paper is to improve vehicle aerodynamics condition,made research and explore in design method and design technique.In design method aspects,two different direction was discussed:how to integrate aerodynamics and aesthetics in forward design,how to improve efficiency and quality in later stage optimization;In design technique aspects,the research focus on CFD simulation and optimization,because witout advanced CFD technique any design method cannot get good result,so the exchange between CAD model and CFD was researched.
The key technology:
1. The integration mechanism between aerodynamics and aesthetics in vehicle body forward design
In the process of vehicle body forward design,if a ideal model is chosen as start point which is perfect in aerodynamics performance,it is a great help for next design process.But it need to sculp and modify on the smooth ideal shape,and this work flow is not accord with traditional habit, so it is necessary to constitute a integration mechanism between aerodynamics and aesthetics.The correlative key technique is:
1) Build up the describing mechanism for style gene.Research the describing mode and definition standard for aerodynamics gene and style gene,establish corresponding describing measure and mathematics model based on bodywork design platform,this model can fulfil the request on exchange and evolution for model describing in CAD platform.
2) Establish integration mechanism in design process.Research how to integrate and syncretize for aerodynamics gene and style gene,include2D integrating and3D integrating.
2. Optimizing holistic aerodynamics layout for finished vehicle
For reducing cost in redesign, the automobile company need to modify the vehicle limited to improve aerodynamics performance; the style project deigned by stylists also need to be optimized.Traditional minor iterative optimizing method need to modify the local part trial and error,is an blindfold and low efficiency method.So a new kind of optimizing method aimed to finished vehicle is necessary.The correlative key technique is:
1) Filtration for non-aerodynamics parts.The actual vehicle include a great deal of non-aerodynamics parts which have limited influence to holistic flow field,but it greatly decrease the efficiency in CFD simulation and optimizing and it is difficult to find out the disfigurement in aerodynamics layout.So it is feasible to filtrate these parts and optimize the basic shape.
2) Distortion technique.It is a modify technique based on control box,it suits the freeform surface in vehicle bodywork and can freely modify the shape,avoids the limitation in minor iterative optimizing method.
3. Improve the efficiency and quality in CFD simulation and optimizing
CFD simulation is a verv important measure in automobile stvle design,from the viewpoint of CAD model and calculating mesh,a new kind of model technology fit for bodywork surface is brought out,it can greatly improve the efficiency in model optimizing and maintenance good precision in CFD simulation.The correlative key technique is:
1) Subdivision mesh technology.In vehice deign progress the traditional nurbs surface have the advantage of high precision and good smoothness,but the model hiberarchy is complicated because the surface is made up of patches,it has the disadvantage of low efficiency and freeness in mesh subdiving process,by introducing new subdivision mesh model instead of nurbs model,the efficiency and quality in CFD simulation can be improved and the precision can keep in acceptable level.
2) The features for calculating mesh.In mesh generating process,in order to improve simulation precision it is feasible to make feature work on mesh object so the calculating mesh is more close to original model and the nodes can snap to geometry information on bodywork.
引文
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