Finite Element Analysis And Lightweight Design For Dump Truck Secondary Frame

Following the continued increasing investment in infrastructure construction of our country, the domestic market demand for heavy-duty vehicles is constantly increasing. As a heavy-duty vehicle, dump truck is easy to be used and has big carrying capacity, so it becomes an indispensable transportation for the construction site. The dump truck sub-frame is a kind of transitional device which is established to alleviate the impact to the main frame from the carriage and cargo, so the strength and stiffness of the dump truck sub-frame have enormous influence to dump truck’s operational performance. In this paper, the type of 2528K heavy-duty mining dump truck designed by a heavy-duty truck company is researched in strength and lightweight based on finite element method (FEM).Firstly, according to drawings provided by the manufacturer, using the finite element software ANSYS, established the solid and finite element model of the main and secondary frame of a truck in accordance with a appropriate simplification principles.Then chosen pure bending condition, combined bending and torsion, and unload conditions as the analytical conditions according to the actual use of the dump truck, carried out the static analysis on the secondary frame of the dump truck . The analysis results show that the maximum stress values of the sub-frame suffered in various operating conditions were smaller than the material yield strength, and there were a considerable surplus, indicated the design of the sub-frame meets the requirements and there is further space of light quantify . This article also carried on the modal analysis on this sub-frame, obtained the first ten second-order natural frequencies and the mode of vibration of the sub-frame, made a appraisal to this vehicle’s dynamic characteristic according to the union modal analysis result.Finally, the section sizes of the longeron and some beams are designed as design variable, ultimate tensile strengths of the sub-frame material as state variables, the total volume of the sub-frame as objective function. The optimal of the dump truck sub-frame is completed with the first-problem of ANSYS. As a result, the total volume reduced 17.58% compared to the origin while the strength of the sub-frame meets its requirements. The research result of this paper have not only provided reference and theoretic basis for improving of 2528K heavy-duty mining dump truck, and solved problems of the enterprise, but also provided reference for the same type tuck.