Finite Element Analysis And Lightweight Research Of Hydraulic Support With 8.2 Meters Large Mining Height

The hydraulic support is an indispensable equipment for fully mechanized coal face.Because the stress of hydraulic support is complex and the traditional test of prototype is affected by the number of measuring point and machining quality, it is difficult to fully reflect the hydraulic support stress distribution. Therefore,it is necessary to carry out the finite element analysis of the whole frame and the main bearing structure. Lightweight research is a reasonable optimization of the hydraulic support structure. By reducing the amount of material used and reducing the weight of the hydraulic support itself, the support performance of the hydraulic support is maintained or increased as much as possible without reducing the reliability of the hydraulic support. The lightweight design of the hydraulic support can not only reduce the labor intensity and facilitate the transport in the mine, but also help to reduce the cost of production to enhance the competitiveness of domestic hydraulic support in the international market.This subject completed the design of 8.2-meter large mining height hydraulic support and the modeling of the main structure. The modeling was carried out using 3D modeling software PRO / E to complete the whole three dimensional model assembly and carry out interference check. The motion simulation of the support was completed based on PRO/E and Adams and the simulation results verified the accuracy of the support design and modeling. The 5 worst working conditions of hydraulic support were both ends of beam loading, beam eccentric loading, base torsional loading, both ends of base loading, top beam torsion loading and both ends of base loading. The stress of the hydraulic support under the 5 most dangerous working conditions could be determined through the finite element analysis,which provided the data support for the lightweight design of the support. Based on the topology optimization in the structural optimization, the top beam and the shield beam of hydraulic support were designed to find the best material layout scheme and the weight was reduced by the material selection under the condition that the hydraulic support can meet the strength requirement under different working conditions. The weight of hydraulic support was reduced by 1.59% after topology optimization. On the basis of topology optimization, the main bearing structures of hydraulic support that included roof beam, shield beam, front link, rear link and base were optimized based on the size optimization in the structure optimization using ANSYS workbench software. The hydraulic support could still be used in the most dangerous working condition and the weight of the hydraulic support was reduced as far as possible, thus achieving the purpose of saving material and reducing manufacturing cost. The weight of hydraulic support was reduced by 1.9% after size optimization. The weight of the hydraulic support reduced by topology optimization and size optimization was 1737kg which accounted for 3.46% of the weight before optimization.The conclusion drawn from analysis and optimization of the hydraulic support with 8.2-meter large mining height indicated that the finite element with modern design theory and method of analysis could replace the prototype test in the traditional design to a certain extent and provide a reliable basis for the design and analysis of hydraulic support and structure optimization.