Finite Element Analysis And Lightweight Optimization Research Of A Dump Truck Frame

The frame of the dump truck is generally constructed by the main frame and the sub-frame,the main frame is the main support part of the dump truck,the sub-frame has the support function for the dump truck,the sub-frame is also a buffer between the cargo box and the main frame of the dump truck,the performance of the frame directly affects the overall performance of the car.Due to the harsh working environment of the dump truck and the changing working conditions,in order to ensure the performance of the car,the frame must meet certain performance requirements.Thus,this paper use HyperMesh/OptiStruct to perform static analysis and modal analysis on the frame to check the strength,stiffness and dynamic performance of the frame,and carry out reasonable structural improvement and optimization design based on the results of static analysis.The main research work of this paper is as follows:Firstly,the frame geometry model was established with Pro/E 5.0 software and rationally simplify it.Import the created frame geometry model into HyperMesh/OptiStruct,and extract the midplane,geometric cleaning,meshing,equivalent simulation of the leaf spring and establish the connection relationship for the frame model so as to establish reasonably finite element model of the frame.According to the actual working conditions of the dump truck,the four conditions of bending,torsion,lifting and unloading are selected for analysis,and the constraints and loads are applied by using HyperMesh/OptiStruct software.The strength and stiffness of the frame are verified by analyzing the stress and deformation of the frame under four working conditions.From the analysis results,it is known that the frame has a low material utilization rate and insufficient strength under torsion condition.The structural improvement and structural optimization of the frame are required.Secondly,the modal analysis is carried out by using OptiStruct.The extract the natural frequency and vibration mode of the first 18 modes of the frame based on the engine and road excitation frequency,and check whether the frame meets the dynamic performance requirements.Finally,in view of the structural problems existing in the dump truck frame,combined with structural characteristics and performance requirements to carry out the optimization and improvement in the following three aspects.In view of the lack of strength of the sub-frame under torsion condition,the structural reinforcement is used to improve the structure.OptiStruct is used to optimize the size of the frame due to the overall low utilization of the frame material and the high stress of the frame under torsion condition.The sub-frame is welded by steel plate,and the manufacturing process of the main parts is bending.In view of this,this paper uses OptiStruct to carry out topography optimization of the frame after size optimization without changing the weight of the sub-frame,thus improving the strength of the sub-frame under dangerous condition.In view of the fact that the material of the main frame longitudinal beam and the lining beam is not fully utilized,the topology optimization is carried out by OptiStruct,and the setting method of the weight reduction hole of the dump truck frame of the similar type is referenced,the weight reduction holes are reasonable and meet the actual production conditions base on the topology optimization results,and check the dynamic performance of the optimized frame.Through the above optimization design,it solves the problem of insufficient strength of the frame under torsion condition,reduces the weight of the frame effectively,improves the strength of the subframe under dangerou conditions,improves economic efficiency and achieves the purpose of energy saving and emission reduction.