Lightweight Study Of Dump Truck Drive Axle Housing

As one of the important methods of energy saving and emission reduction,lightweight technology has been widely used in traditional fuel vehicles and new energy vehicles.Dump truck drive axle housing is an important part of the chassis system,its lightweight can effectively reduce the weight of the vehicle,reduce production costs;At the same time,the unsprung mass is reduced to improve the ride stability and comfort of the vehicle.Therefore,the research on the lightweight of the drive axle housing has important practical significance in engineering.Solid Works and ANSYS Workbench software were used to model the driving axle housing parametrically,and then mesh was divided and boundary conditions were added.Finite element simulation was carried out for four working conditions of the axle housing.The results show that the maximum stress of the axle housing is 133.7MPa,which is smaller than the allowable stress of the material of the main axle housing.The maximum deformation of axle housing per meter of wheel base is 1.002mm/m,which is less than the standard requirement of axle housing of 1.5mm/m.The first-order natural frequency of the axle housing is 143.7Hz,which is much higher than the general excitation frequency of the road surface.The axle housing has room for lightweight.A multi-objective genetic algorithm based on response surface was used to optimize the axle housing deterministically.Firstly,the correlation analysis method of orthogonal test parameters was used to analyze the influence of axle housing size parameters on performance parameters.Based on the Optimal space-filling Design,the sample points are selected,and the response surface is constructed by Kriging interpolation method,and the deterministic coefficient R² is calculated.The results show that:（1）The height of the plate spring seat at the upper part of the axle housing is T1,the thickness behind section A is D1,the thickness before section A is D2,the height above section A is D3,and the height above section B is D5.The above five variables have A great influence on the performance parameters and are selected as the optimal design size.（2）The R² of the verification points for the response surface model is greater than 0.95,which is acceptable for engineering problems.Then,the design parameters,optimization objectives and constraint conditions of the axle housing are set.A multi-objective genetic algorithm（MOGA）based on Pareto sequencing was used for multi-objective optimization.Nine groups of alternative size optimization solutions are obtained.Six sigma reliability analysis method based on Monte-Carlo sampling was used to analyze the reliability of nine groups of alternative deterministic optimization solutions.The results show that:（1）No.9 alternative optimal solution is the final optimal size of axle housing;（2）Compared with the original axle housing,the optimized axle housing body mass is reduced by 11.84%.The maximum stress P_max and maximum deformation D_max of the axle housing are the minimum values and their reliability is high.（3）When carrying out deterministic optimization of axle housing,the maximum stress of axle housing should be set as the first optimization objective and the axle housing quality as the second optimization objective.