For achieving vehicle lightweighting, the cross car beam (CCB) assembly is redesigned for the substitution of extruded magnesium alloy for steel, in which extruded parts and stamped parts are designed separately due to different processes with their material and connection process determined.A FE model for CCB assembly is set up and a comparative medal analysis and crash intrusion analysis are conducted.The bending forming of tubes is also simulated with a bending simulation model built.The results show that magnesium alloy substitution design meets the requirements on lightweighting, medal behavior, crash safety and manufacturability of CCB.%为实现汽车轻量化,对钢制仪表板横梁骨架总成进行了镁合金替代设计.依据制造工艺将镁合金仪表板横梁骨架按挤压件和冲压件分别设计,并确定了镁合金材料及连接工艺;建立镁合金仪表板横梁骨架总成的有限元模型,进行模态对比分析和碰撞侵入量分析;建立仪表板横梁管材的弯曲仿真模型,模拟管坯的弯曲成形.结果表明镁合金替代设计满足仪表板横梁的轻量化、整体模态、碰撞安全以及可制造性的要求.
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