Finite Element Analysis And Optimal Design For Metal Structures Of Bucket Wheel Stacker-reclaimer

Along with the continuous development of China's economic construction,the needs of iron, coal, cement and other basic raw materials has upward trend accelerated. In ports, power plants and other places, the throughput of bulk materials are staggering, and relying on Loader and vehicle matching loading and unloading operations have been unable to meet the requirements. Under such a background, the demand for Bucket becomes increasingly prominent. Bucket is a continuous and efficient bulk material handling industrial equipment, is now widely used in mining, metallurgy, electricity, transportation, building and chemical industry. Upper metal structure is the main component of bucket wheel machine, and this part is more complex stress state, which prone to open welding, cracks and other failures, These troubles impact so high performance requirements of the metal structure should be increased. Therefore, we should not consider only from the stiffness and strength, we must also consider the dynamic characteristics of bucket. Modern engineering and technology is moving in a safe, reliable, practical and standardized development. With the design of bucket, it is necessary to consider various factors in improving the performance of bucket .Designers should shorten the design cycle and reduce the design cost as far as possible.As a large general-purpose finite element analysis software, ALGOR are widely used in various industries to design, structure analysis, simulation of mechanical movement, the analysis covers static, dynamic, fluid, heat conduction, electromagnetic fields, pipeline design process. The use of ALGOR software in the secondary development of friendly interface, and for research papers Bucket by this particular object, use C language as a programming language, using VC6.0 as a programming tool, combined with the Script Language ALGOR software to complete this process preparation. Procedures simple intuitive interface is easy to operate, the procedure can be completed finite element model of the automatic assembly, load and add a constraint, the results of automatic analysis and secondary processing, reduces the labor intensity of analysts, it also reduce human error factors caused by repeated interventions,the program laid a foundation for the optimization of Bucket.This paper was based on the finite element method and the basic principles of mechanics, done a reasonable finite element analysis to the initial design of the cantilever bucket(DQ600/900·30) steel structure in application with software Algor16 The use of ALGOR software and HyperMesh software establish bucket finite element model, which makes a reasonable simplification under the premise of the real structure of the model state, replaced hinge pin with beam and bar combination, the force of the flange plate with a simple beam element replaced bracing structures, such as rod and bar forces in accordance with stroke unit or beam element simulation. Thus reduces the model size and improves the speed. Use Algor16 software completed equipment in self-weight, normal work and overload work three load cases of linear static analysis. This paper accomplished the linear static analysis with ALGOR16 software in three load case of normal work overload work and self-weight. Each load case is divided into a boom in the level of the horizontal,supine and prone three load cases. The results from the displacement, the forearm frame and the overall weight of the rigid frame get larger displacement, and their deflections are very small, the rigidity of these two parts can be seen very well. The results from the stress, forearm rear arm and weight arm in the Von Mises stress are below 130MPa, especially forearm stress plane is not more than 75MPa, the fact proved higher intensity of forearm frame and its strong load-bearing capacity. The Von Mises stress of Lizhu are most below 180MPa, but in the plate bending, stress produced a higher concentration, which did not exceed allowable stress safety, subject to the structural improvement. Worst beam stress did not exceed the security required. Worst stress beam did not exceed the safe allowable stress, the top of the beam column connections of individual nodes with a high-stress and connect analog nodes related to surface connection, which can not be accepted.This paper completed the dynamic analysis for upper metal structure of the bucket and also got the dynamic characteristic parameters of upper part, given the structure of the top ten order vibration mode. When bucket is working, which have great influence on its external incentives are bucket wheel reclaimer at the time of vibration, the drive roller and the rotating drum divert a large number of vibration and rotation of the vibration roller. Comparing to the exciting outside world, the frequency differences are bigger, which will not give rise to the phenomenon of resonance. This paper provided a reasonable basis for designers to understand their mode shapes and natural frequencies to avoid certain frequency bands.In response to these issues, this paper puts forward the corresponding measures in optimizing the upper part of bucket:First, widening the width of column web to enhance the overall stiffness of column;Second, thickening of column flange thickness and adding ribs at the bending plate to enhance the strength of column;Third, moving down the location of hinge pin between the column and the weight arm, so that the structure of center of gravity down, shortening the length of weight arm.All of the next improvement are made on the basis of previous improvement, and when the completion of the optimization measures, the column displacement X is only 30.7mm, and the column bending stress plate dropped to 178.2MPa, All the results meet the design requirements and also proved the optimizations measures done by paper are reasonable.By applying the finite element analysis software, for the analysis and optimization of bucket is a good way, can be found design deficiencies and defects .It also guides the designers to improve the design, thus reducing design cost and shorten the design cycle.