Study On Lightweight Of Heavy-duty Dump Truck Based On Structural Optimization And High-strength Steel Application

This research mainly studied on the lightweight of the dump truck box and the frame. The effect of lightweight was good by structural optimization and the equivalent design of high-strength steel. The formula of thickness replacement was derived, and its practicality and user-friendliness have been verified.First of all, the lightweight research background of the heavy truck was introduced, and the significance of this research was explained. According to the situation at home and abroad, the research methods of the finite element technology and the application of new materials were put forward.Secondly, according to the analyzing the structural of the dump truck box and the frame, the dump truck box and frame geometric model were built on the basis of the drawing provided by the client. The main structure of the dump truck box and frame was meshed by Shell63 elements, and Solid45 elements were used to mesh other structure. Considering the instant lifting conditions in which the dump truck box suffered the most difficult moment, it was chosen as the condition to calculate. Stress and displacement of the dump truck box were obtained, which can provide a reliable reference to the product designing process of the enterprise.Next was the structural improvement. Considering the situation of low stress level, according to the serious stress concentration phenomenon, a series of structural improvement measures were taken to the bottom and both sides of the dump truck box. Consequencely, the serious stress concentration phenomenon was eliminated. At the same time, the distribution of stress became much more reasonable. And the quality of the dump truck box reduced 820.43kg.Then, on the basis of the structural improved box, a size optimization research was carried to the dump truck box. Consequencely, the bearing capacity was not declined, and the box weight was reduced 244kg. In a word, the mass of the dump truck box was reduced 1064.43kg, which was 24.5% of the former box.At last, the equivalent design of high-strength steel was carried to the structural improved box and the frame. The thickness of shell was replaced by the formula of thickness replacement. Finally, the lightweight research achieved good results. The box weight was reduced 1099.42kg; the qulity of the frame reduced 286.68kg, which is 15.13% of the former frame.