Abstract: To achieve lower energy consumption of new energy vehicles, this paper takes a certain new energy sports utility vehicles (SUV) as the basic model to investigate the replacement of the hot-formed steel door anti-collision beam with an aluminum profile filled with structural foam. Finite element simulation software ANSA and LS-DYNA are employed to conduct a 50 km/h side impact analysis on the foamed aluminum profile scheme. The results show that the optimal intrusion amount is reduced from 92.61 mm to 71.54 mm, and the optimal average intrusion velocity is decreased from 3 731.44 mm/s to 3 441.93 mm/s. The foamed aluminum profile scheme achieves a weight reduction of 6.8 kg while delivering superior safety performance. This paper verifies the feasibility of the foamed aluminum profile anti-collision beam through simulation, providing a solution for the lightweight research of new energy vehicles.

Key words: LS-DYNA; side impact; door anti-intrusion beam; foam-filled aluminum profile; lightweight

摘要： 为实现新能源汽车更低的能耗，文章以某新能源运动型多用途汽车（SUV）为基础模 型，将车门防撞梁从热成型钢换成填充结构泡沫的铝型材，利用 ANSA 和 LS-DYNA 有限元 仿真软件对该泡沫铝型材方案进行 50 km/h 侧面碰撞分析。研究结果表明，最优侵入量从 92.61 mm 降低至 71.54 mm；最优平均侵入速度从 3 731.44 mm/s 降低至 3 441.93 mm/s，泡沫 铝型材方案能够减重 6.8 kg 且有着更优的安全性能。文章通过仿真验证了泡沫铝型材防撞 梁的可行性，为新能源汽车的轻量化研究提供解决思路。

关键词: LS-DYNA；侧面碰撞；车门防撞梁；泡沫铝型材；轻量化