Lightweight stamping parts for new energy vehicle chassis

　　Lightweight Stamping Parts for New Energy Vehicle Chassis: Technological Innovation Drives Efficient Energy Conservation

　　In the era of rapid development of new energy vehicles (NEVs), lightweighting has become a core strategic direction to enhance battery life, reduce energy consumption, and improve overall performance. As the "skeleton" of NEVs, the chassis bears the dual responsibilities of load-bearing and safety protection, and its lightweight upgrading is crucial. Lightweight stamping parts, with their advanced material application, innovative forming processes and excellent structural performance, have become a key breakthrough in the lightweight transformation of NEV chassis, injecting strong momentum into the high-quality development of the industry.

　　1. Core Demand: The Inseparable Connection Between Chassis Lightweighting and Stamping Technology

　　The performance of NEVs is closely related to the weight of the whole vehicle. According to industry data, for every 10kg reduction in the weight of the vehicle body, the battery life can be increased by about 5-8km; the weight reduction of the chassis, as a key component, directly affects the energy efficiency and handling stability of the vehicle. Traditional chassis stamping parts, mostly made of ordinary carbon steel, are difficult to balance the needs of lightweighting and structural strength.

　　Lightweight stamping parts for NEV chassis solve this contradiction through systematic innovation. They not only reduce the weight of components by 20%-40% compared with traditional parts, but also ensure that the tensile strength, fatigue resistance and impact resistance meet or exceed the safety standards. Meanwhile, the stamping process, with its advantages of high production efficiency, high forming precision and strong batch stability, provides reliable guarantee for the large-scale application of lightweight chassis parts, which is highly recognized by mainstream NEV manufacturers such as BYD, Xpeng and Dongfeng Voyah.

　　2. Technological Core: Multi-dimensional Innovation Empowers Lightweight Performance

　　2.1 Material Innovation: The Foundation of Lightweight and High Strength

　　The lightweight of stamping parts first relies on the precise selection and application of high-performance materials. At present, the industry has formed a multi-material matching system based on "high-strength steel + aluminum alloy + composite materials", realizing the optimal allocation of performance and weight:

　　Advanced high-strength steel (AHSS): Through the hot stamping process, the tensile strength of high-strength steel can reach more than 1500MPa, which is equivalent to bearing 15 tons of weight per square centimeter. While significantly improving the safety performance, the weight of the parts can be reduced by 30%. It is widely used in key stress-bearing parts such as chassis frame and anti-collision beam.

　　High-performance aluminum alloy: Materials such as aviation-grade 7075 aluminum alloy and ALUMEC 100 aluminum alloy have become important choices for lightweight stamping parts. Their density is only 1/3 of that of steel. After solution aging and other heat treatment processes, their tensile strength can reach more than 300MPa. The aluminum alloy B-pillar and sub-frame produced by stamping can reduce the weight by nearly 2/3 while ensuring the performance, and have excellent corrosion resistance.

　　Thermoplastic composites: Taking PPS (polyphenylene sulfide) as the matrix and continuous carbon fiber as the reinforcement, the composite stamping parts have the comprehensive advantages of high strength, high rigidity and ultra-lightweight. The battery box upper cover made of this material can withstand 1200℃ flame combustion for more than 10 minutes, and the weight reduction rate compared with the traditional steel scheme exceeds 60%.

　　2.2 Forming Process Innovation: Precision Control Ensures Performance Stability

　　Advanced stamping processes are the key to realizing the performance potential of lightweight materials. The industry has formed a series of innovative process systems centered on "precision forming + intelligent control":

　　Hot stamping quenching integrated process: This process realizes the "ice-fire transformation" of materials - heating the steel plate to 930℃ in a precision heating furnace with temperature difference within ±5℃, then stamping and forming immediately, and cooling to room temperature in 8 seconds through the built-in cooling water channel of the mold to complete the quenching strengthening. This process makes the ordinary steel plate complete the leap from "ordinary" to "super strong", and the produced stamping parts have excellent dimensional precision and structural stability, which is the core technology for the production of high-strength lightweight chassis parts.

　　Laser tailor-welded stamping technology: For complex chassis parts such as door rings, the traditional process requires multiple stamping and welding of multiple steel plates. The laser tailor-welded technology can seamlessly splice steel plates of 7 materials and 5 thicknesses into an integrated plate first, and then complete the forming with one stamping. This technology reduces the production process by 75%, the comprehensive cost by at least 20%, and effectively avoids the performance loss caused by multiple welding.

　　Digital precision stamping technology: The integration of CNC precision control, 3D scanning detection and other technologies realizes the full-process monitoring of the stamping process. The multi-pass progressive rolling process is adopted for thin-walled stamping parts, which controls the single-pass deformation to 2%-5%, ensuring the uniformity of wall thickness with an error of ≤0.1mm. After forming, the 3D scanning technology is used for full-size inspection to ensure that the dimensional tolerance meets the IT7 level requirements.

　　2.3 Post-processing Technology Upgrade: Synergistic Enhancement of Durability

　　In order to further improve the service life and reliability of lightweight stamping parts, targeted post-processing technologies are adopted for different materials: For high-strength steel stamping parts, stress relief annealing is carried out at 550-600℃ to eliminate 60%-80% of welding residual stress; for aluminum alloy stamping parts, hard anodizing treatment is adopted to form a 25-50μm ceramic layer on the surface, with hardness exceeding 400HV; for composite stamping parts, surface coating technology is used to enhance wear resistance and environmental adaptability.

　　3. Application Value: Empowering the High-quality Development of NEV Industry

　　Lightweight stamping parts for NEV chassis have been widely used in key systems such as suspension, battery pack support and anti-collision, and have achieved remarkable application effects:

　　In terms of energy conservation and battery life improvement: The lightweight sub-frame produced by Linjite Company reduces the weight by 20% compared with traditional steel parts. After being installed on Chery V23 models, the vehicle's battery life is increased by 30km. For large-scale NEVs, the popularization of lightweight chassis stamping parts can reduce the power consumption by 0.6kWh per 100km, effectively alleviating the range anxiety of users.

　　In terms of safety improvement: The hot-formed high-strength steel anti-collision beam and frame stamping parts can effectively resist deformation during collisions, ensuring the integrity of the passenger compartment. The aluminum alloy and composite stamping parts have excellent energy absorption performance, which can reduce the impact force transmitted to the body during collisions and improve the passive safety level of the vehicle.

　　In terms of industrial efficiency enhancement: The stamping process has the advantage of high batch production efficiency. The matching of lightweight materials and innovative processes not only reduces the weight of parts, but also reduces the production cost and cycle. At present, leading enterprises have built 9 hot stamping production lines, forming a leading production capacity in the country, which can efficiently meet the supporting needs of mainstream NEV manufacturers and promote the upgrading of the entire industrial chain.

　　4. Future Trend: Towards System-level Lightweight Integration

　　With the deepening of NEV intelligence and electrification, lightweight stamping parts for chassis are moving towards the development direction of "system-level integration + multi-material synergy". On the one hand, they are closely integrated with integrated die-casting technology, integrating multiple stamping parts into an integrated component, further reducing the number of connections and improving structural stiffness; on the other hand, through topological optimization design, materials are distributed according to mechanical paths, realizing "smart material use" and maximizing the lightweight effect.

　　At the same time, the research and development of new materials such as nano-structured aluminum alloys and carbon fiber-reinforced composites, and the innovation of new processes such as rapid thermoforming will continue to promote the performance upgrading of lightweight stamping parts. In the future, lightweight stamping parts will not only be a key component of chassis lightweighting, but also an important support for the NEV industry to achieve the goals of carbon peaking and carbon neutrality.

　　As a core carrier of chassis lightweight technology, lightweight stamping parts are redefining the performance boundary of NEVs with continuous technological innovation. In the future, with the joint efforts of materials, processes and design, they will surely inject more powerful impetus into the high-quality development of the global new energy automobile industry.

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