| Based on the corporation project of XXX off-highway wide-body mine dump truck,this paper took deeply research on its frame fracture failure analysis andstructure improvement. As the main implement applied in mine transportation, theoff-highway wide-body mine dump truck is famous for its high volume and largecapacity. In addition, off-highway wide-body mine dump truck also has lots ofadvantages such as environmental suitability, operation stability, powerfulmotivation and so an. Attribute to the impressed performance, we can easilycapture the figure of this device around the mines, especially the severe workingcondition, for instance, the uneven road. As consequence, it leads to fracturefailure of the frame which sustains the main loads of equipment operation andplays a particular part of off-highway wide-body mine dump truck. As well itsfunction directly influences the life of the truck and reflects the technicallevel of the vehicle. In this paper, the mass of the wide-body mining dump truckhas an unladen weight of21t, a maximum load capacity of80t, and a normal speedof10km/h when carrying full loads or30km/h when empty. However, after fiveto six months in service, cracks tend to appear in the frame, which results insignificant downtime and makes the enterprise suffers huge economic losses. Inorder to find out the cause of the frame fracture, and puts forward the improvedstructure design, this paper focus on the frame rigidity and strength of thewide-highbody mining dump truck. Combined with the finite element static linearanalysis, dynamic stress analysis of multi-body dynamics, the vehicle of thestatic and dynamic test and the analysis of fatigue life prediction, eventuallyformed a complete set for the wide-body mining dump truck frame fracture failure analysis system and provide a reference basis for future engineering practice.This paper is devided into seven parts.The first chapter introduces the research background and significance of theoff-highway wide-body mine dump truck, a detailed description of its structureand composition and the status and trends of development. Through the domesticand foreign research on off-highway wide-body mine dump truck and the analysisand comparison of its frame failure and other problems, the article proposes itsresearch direction and content.The second chapter mainly discusses the frame and suspension stiffnessmatching problem. Because of the the main load of frame was passed by thesuspension, so the suspension as an important power transmission components,which is connected to the frame, its stiffness directly affect the stiffness ofthe frame. In the following of describing the characteristics of the suspensionsystem, selecting and determining the suspension type, the stiffness matchingbetween the front and rear suspension, and the stiffness matching between frameand suspension stiffness matching are studied. In the following of determiningthe right stiffness of suspension and frame, subsequent analysis the static anddynamic of suspension and frame used in this stiffness.The third chapter is the linear finite element static analysis of framefailure problem. Combined with Pro/E, HyperMesh, ANSYS to establishe finiteelement model, and used proper unit types to simulate the various structure andboundary conditions, chose typical working condition to analysis to failureframe, combind the stress intensity factor theory and stress concentration factortheory to find the causes and location of failure of frame, then put forwardrational improvement schemes.At the same time, compared the later frame finiteelement static analysis and modal analysis with the former one.The fourth chapter is based on multi-body dynamics simulation analysis anddynamic stress of the frame.This chapter, combining the theory of multi-body dynamics, establishs the highway wide-body dump truck vehicle lane virtualprototype model, the simulation analysis of the two kinds of typical workingcondition of the road surface, preparing for later analysis of the fatigue lifeprediction, namely extraction frame load transfer point load spectrum.The fifth chapter is the test of key technology. In order to verify therationality of the static finite element analysis and multi-body dynamiccalculations, the test is needed. According to the comparative analysis, finiteelement static analysis results and static test results are similar, the curveof multi-body dynamics simulation results and field test in the standard testcurve coincides with that, finite element analysis and multi-body dynamicssimulation are correct. Through the dynamic test on the mining field, find thestress mapping coefficient, use this to get the dynamic data of the invalid frame.The sixth chapter is the predict analysis of the fatigue life of the frame.By using the multi body dynamics simulation analysis of ADAMS/VEW above, pickup the load spectrum of the point of the load on the frame.through the dynamicload simulation calculate the alteration process of load over time.Estimate thefatigue life of the frame by using the ncode fatigue life analysis program.theresult shows that fatigue life of the frame is about five and a half month alongwith the realistic invalid time, which means the methord and the result isamenable. And the live of improved frame also reach the design requirement.The seventh chapter summarizes the full paper, at the same time puts forwardsome prospects in future research.This paper has three innovations:(1)Integrate finite element static analysis, ADAMS multi-body dynamicssimulation analysis, static and dynamic test and fatigue life prediction analysis,in this paper, we provide a complete set of analysis method for the off-highwaywide-body mine dump truck frame failure analysis, provide the reference and basisfor the similar structure in the future. （2）Author set up a series of static testing and dynamic testing of standardfield and mining area on off-highway wide-body mine dump truck frame and majorparts, along with the further verification of CAE method. As a kind of completeand huge testing process, the static testing is able to provide reference forthe further research.（3）The time-load history curve extracting from dynamic analyses input asthe load spectrum of fatigue calculation and thus obtained the conclusion whichproved the fatigue life of failure structure according with the actual fracturetime. This conclusion can be used to forecast the fatigue life of the improvementframe, which generates a significant implication for the research of engineeringvehicle. |
PDF Full Text Request