Abstract: On the premise of not changing the current design structure, the sheet thickness of some commercial vehicle body structures is optimized using computer aided engineering (CAE) analysis optimization and reliability test, and the application of lightweight technical solutions with the lowest mold modification cost is achieved. The indicators and results of performance analysis are used as the response and constraints of sensitivity analysis,topology and size optimization, respectively applying multi-condition optimization design tools considering comprehensive performance (stiffness, modal, crash safety). Conducts CAE analysis and optimization with goal of minimizing the total body mass, and determines the optimization scheme. The optimized structure is verified by reliability test, which verifies the feasibility of the optimization scheme. In the end, achieves the weight reduction of 14.1 kg, a decrease of 4.7%, and the maximization of economic benefits.

Key words: Commercial vehicle; Lightweight body; Performance analysis; Sensitivity analysis; Topology optimization; Size optimization; Reliability test

摘要： 在不改变当前设计结构的前提下，采用计算机辅助工程（CAE）分析优化和可靠性试 验相结合的方法对某系列商用车车身结构进行板料厚度的优化，从而实现模具更改成本最低 的轻量化技术方案应用。应用考虑全面性能（刚度、模态、碰撞安全性）的多工况优化设计 工具，以性能分析的指标和结果分别作为灵敏度分析、拓扑及尺寸优化的响应、约束，以车 身总质量最小化为目标进行 CAE 分析优化，确定优化方案。优化后结构通过可靠性试验验证， 验证了该优化方案的可行性。最终实现降重 14.1 kg、降幅 4.7%和经济效益最大化目的。

关键词: 商用车；车身轻量化；性能分析；灵敏度分析；拓扑优化；尺寸优化；可靠性试验