現今車輛朝向電動車發展，而減輕車體重量成為現在設計上重要的需求，本文研究針對車輛底盤零件上控制臂作為輕量化的目標，上控制臂Type-A，材質為汽車結構鋼、塑膠，為改善產品結構強度及輕量化，設計出上控制臂Type-B，材質改為全金屬，以提升結構強度，藉由Ansys有限元素分析軟體進行結構分析，比較Type-A及Type-B之剛性，確保Type-B優於Type-A，後續使用Design Expert設定因子水準進行分析設計並找出最好的輕量化參數。
本研究利用Ansys有限元素分析軟體，分析上控制臂結構求出等效應力，在等效應力不低於材料降伏強度情況下更改材料，加上輕量化設計，並使用Design Expert軟體進行分析設計，之後再將Design Expert所得出分析排列組合進行有限元素分析，在將模擬結果進行殘差分析、變異數分析，確定分析結果是否有常態分配以及探討因子之間是否存在交互作用，最後在使用Design Expert分析得出最好的輕量化參數。
本研究使用有限元素分析配合最佳化設計軟體，可在實際做出產品前便可模擬出結構強度，以便降低產品設計錯誤風險、產品成本、產品重量，以及提升產品開發效率。

Nowadays, the development of vehicles is moving towards electric vehicles, making weight reduction a crucial requirement in current design. This study focuses on the lightweighting of the upper control arm, a component of the vehicle chassis. The upper control arm Type-A, made of automotive structural steel and plastic, was designed to improve product structural strength and achieve lightweighting. The redesigned upper control arm Type-B, made entirely of metal, aims to enhance structural strength. Structural analysis was conducted using Ansys finite element analysis software to compare the rigidity of Type-A and Type-B, ensuring that Type-B outperforms Type-A. Subsequently, Design Expert was used to set factor levels for analysis and design, identifying the optimal lightweighting parameters.

This study utilized Ansys finite element analysis software to analyze the structure of the upper control arm and determine the equivalent stress. Materials were changed under the condition that the equivalent stress does not fall below the material yield strength, combined with lightweight design. Design Expert software was then used for analysis and design. The combinations derived from Design Expert were subjected to finite element analysis, followed by residual analysis and variance analysis of the simulation results to determine if the results followed a normal distribution and to explore interactions between factors. Finally, Design Expert was used to derive the optimal lightweighting parameters.

This study demonstrates that using finite element analysis in conjunction with optimization design software allows for the simulation of structural strength before actual product manufacturing. This approach helps reduce the risk of design errors, product costs, and product weight, while enhancing product development efficiency.

摘要......i
Abstract......ii
誌謝......iii
目錄......iv
表目錄......vi
圖目錄......vii
1 第一章 緒論......1
1.1 研究背景與動機......1
1.2 現況分析與發展趨勢......2
1.3 研究流程......2
2 第二章 文獻探討......4
2.1 控制臂之介紹......4
2.1.1 控制臂製程......4
2.2 材料種類......5
2.2.1 汽車結構鋼......5
2.2.2 工程塑料......5
2.2.3 鋁合金......5
2.3 有限元素法簡介......5
2.3.1 靜態結構分析公式......6
2.4 六個標準差......6
2.4.1 變異數分析(ANOVA)......6
2.4.2 殘差分析與診斷圖......7
2.4.3 影響力分析......7
3 第三章 設計流程與方法......8
3.1 設計流程......8
3.2 分析過程......9
3.2.1 模型介紹......9
3.3 結構分析......12
3.3.1 分析基本假設......12
3.3.2 模型材料性質......14
3.3.3 網格數量與品質......14
3.3.4 結構分析邊界條件設定......15
3.4 Type-A 與Type-B結構強度比較......16
3.5 因子與水準設計......18
3.5.1 輕量化設計......18
3.5.2 模型材料性質......20
3.6 分析設計......20
4 第四章 結果與討論......21
4.1 結構分析結果......21
4.2 變異數分析(ANOVA)......22
4.3 殘差分析......24
4.3.1 殘差之常態分配檢查......24
4.4 診斷圖......27
4.4.1 殘差與預測值檢查......27
4.4.2 殘差與分析順序檢查......29
4.4.3 預測值與實際值檢查......31
4.4.4 Box-Cox轉換檢查......32
4.4.5 殘差與因子檢查......34
4.5 影響力分析......40
4.5.1 LEVERAGE與分析順序檢查......40
4.5.2 DFFITS與分析順序檢查......41
4.5.3 DFBETAS與分析順序檢查......43
4.5.4 COOK’S DISTANCE與分析順序檢查......44
4.5.5 超出警戒線之資料點檢查......45
4.6 最佳化參數設計......46
4.7 最佳化參數驗證......52
4.8 分析結果比較......53
5 第五章 結論與未來展望......55
5.1 結論......55
5.2 未來展望......55
6 參考文獻......56
7 Extended Abstract......57

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