Addressing the poor manufacturability issues of brackets with sheet metal welding connection in the commercial vehicle industry,a novel structural design and development approach was employed using a combination of structural stress finite element analysis and casting process simulation.Through structural and process design,as well as material selection and optimization,the newly developed nodular iron integrated connection bracket casting exhibited no shrinkage or looseness defects after X-ray inspection.The casting quality was excellent,achieving a lean target of 23％weight reduction and 25％cost reduction compared to the current sheet metal welding structure.It also had improved load-bearing reliability.Vehicle reliability verifi-cation indicated that the newly developed structure met the overall vehicle reliability requirements,fulfilling the vehicle quality standards.
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