Structural Lightweight Research On Great Tonnage Dump Truck

Firstly,the background of structural lightweight research of the great tonnage dump truck was introduced in the paper.After that,considering the developing tendency and actual requests of the enterprise,the main goal and signification of research on this subject were elaborated.Based on analyzing the present research situation at home and abroad,the main content of this paper was proposed.Then,the basic research methods of the lightweight of the dump truck was analyzed in the paper.Shape optimization,topology optimization and size optimization were introduced.At the same time,the optimization module and method of topical FEA software were introduced.By analyzing the feature of the dump truck box and frame,the method of structure improving design and size optimization were chosen to lightweight the dump truck box and frame separately,the final lightweight program was established.According to the drawing provided by the client,box and frame geometric model were built.The main structure of the box and frame was meshed by shell elements,and other structure was meshed by solid elements.Then,considering the computing time,accuracy and scale,the FEA computing model was built according to the actual working condition of the dump truck.After building the computing model of the box,finite element analysis was carried under the loading case of initial lifting condition.Stress and displacement of the box were obtained,which provides a reliable reference to the product designing process of the enterprise.At the same time,according to the situation of low stress level and the serious stress concentration phenomena,a series of structural improvement measures were taken to the bottom,side,former and back board.After that,not only the serious stress concentration phenomena was eliminated,but also the distribution of stress become much more reasonable,the quality of the box has reduced significantly,totally reduced mass was 342.8kg,which was 11.1%of the box.Then,on the basis of built the frame computing model,the frame finite element analysis was carried under the condition of bending,six kinds of bending and torsion condition,and three kinds of lifting condition.Stress and displacement of the frame were obtained under every loading condition,which provided reliable reference to the frame lightweight design.Then,a structural improvement design was carried to some stress concentration areas and achieved good results.Finally,considering the low level of frame stress and combined with the actual requests of the enterprise,a size optimization research was carried to the sub-frame, which setting the thickness of some components as design variables,the element maximum stress under every load cases as state variables and the whole frame volume as objective function.After that,the frame weight was reduced 180.5kg, which was 20.35%of the vice-frame.After the lightweight design of the box and sub-frame,the mass of tonnage dump truck was reduced 532.3kg(which is 13.2%) under the condition that the bearing capacity was not declined.