Lightweight Design Of Dump Truck Compartment Based On Hyperworks

With the increasing development of national mining engineering,Dump trucks have become more and more popular.Due to the heavy weight of dump trucks,fuel consumption has become one of the issues that users are very concerned about.Therefore,the lightweight design of dump trucks is the main development direction of the manufacturers.According to the research,it is found that the weight of the dump truck compartment occupies the majority of the weight of the entire vehicle.Lightweight design is an effective way to reduce the production cost and fuel consumption of the dump truck.This paper takes a mine dump truck carriage as the research object.This type of dump truck is damaged in batches after being put into use.Through field investigation and combined with finite element calculation,the carriage structure is improved from three aspects: structural optimization,size optimization and replacement of lightweight materials.At the same time,the strength and stiffness of the new carriage under dangerous conditions have been checked constantly.Finally,the problems of serious deformation and cracking of key parts in the use of the dump truck were solved,the lightweight design of it has been realized as well,which enhances product competitiveness of this company.The conclusions of this paper are as follows:(1)Three-dimensional modeling and finite element simulation analysis of the original dump truck.The failure information of dump truck was collected through field research,and the main forms and locations of damage were preliminarily mastered.According to the relevant technical standards,the statics analysis and the dangerous working condition analysis of the original carriage were carried out under five typical working conditions(constant speed,sudden braking,turning,lifting 0°and lifting 11°)experienced by the dump truck in the actual transportation process.The results show that the stress level of the original carriage is low,but the stress concentration is easy to occur in some constrained positions with small cross-sectional area,which makes the carriage stress increase.The front panel assembly has the largest stress and deformation under the condition of sudden braking.There is a large material surplus of the front panel assembly.The stress and deformation of the side plate assembly are the largest under the turning condition,and each component meets the requirements of use with Large material surplus.The bottom plate assembly has the largest stress and deformation under the condition of lifting 11°,and the phenomenon of stress concentration is obvious.The longitudinal beam and the rotating support beam cannot meet the strength requirements.The unreasonable structure of the bottom plate assembly leads to deformation and cracking of the carriage.(2)Lightweight design of the dump truck compartment.At first,improve the beam structure of bottom plate assembly of original dump truck compartment,improve the two dangerous components of the rotating support beam and the floor longitudinal beam with the method of material replacement and variable section,to make it meet the strength and rigidity requirements.Then two kinds of lightweight solutions for dump truck compartment are proposed.The first one is based on OptiStruct module to optimize the overall size of the carriage,and combined with dangerous working conditions for finite element simulation.The results show that: the stress and deformation of each component of the new carriage obtained by the size optimization meet the strength and rigidity requirements.The total weight of the new carriage is 5.7t,and the overall weight reduced by 12.3%.The second scheme proposes a new type of sandwich panel carriage structure.by using DP780high-strength steel metal sandwich panel replace the carriage side panel,and perform static strength analysis under turning conditions.The results show that: compared with the first case.the maximum deformation of the sandwich panel carriage structure has been increased,but the strength and the rigidity of the carriage still meet the standard requirements.The final weight of the sandwich panel carriage is 5.3t,the overall weight loss of the compartment is 18.5%,the weight reduction effect isobvious.(3)New carriage body welding production and the quality tracking inspection.Combined with the actual production situation,although the weight reduction effect of the sandwich panel structure is better,due to the complicated welding process of the sandwich panel and the high production cost.The production process of the carriage obtained by size optimization is more mature.Therefore,the manufacturer finally chose the first scheme,and conduct quality tracking detection for the structure.The results showed that after being put into use,the car has no serious problems such as deformation and cracking,and its performance is better than the original carriage structure.It also verifies the rationality of the lightweight structure design of the carriage and the accuracy of the finite element analysis results.Based on the field research and finite element calculation,this paper starts from the existing damage problems of dump truck,and puts forward some integrated solutions,such as finite element modeling,static analysis,damage form analysis,lightweight design,welding production and quality tracking,to provide useful reference for the lightweight design of dump truckt.