Heavy-Duty Dump Truck Carriages Optimization Design

Carriage is an important part of the dump truck, at present there are two main types of carriage:rectangular carriage which cross section is rectangular, and U type carriage which box section is u-shaped. Beacause of overloading, our country’s dump trucks are used in the bad conditions, the carriages are prone to failure; as a result of increasing the strength, the quality of carriage, can account for30%of the dump truck kerb mass. Large quality carriage will have an impact on the dump truck driving safety and fuel economy. Therefore, the optimization design of carriage, to improve dump truck performance has positive significance.This paper makes the TY-1heavy-duty dump truck rectangular carriage and U type carriage as the research object, carries out the following research work.First of all, establishing two finite element models of the dump truck carriage in HyperMesh, and a static analysis is made on the instant lifting conditions. Setting the boundary condition based on the dump truck working state, analyzing strength and stiffness of carriages with20t and35t loads. Conducting finite element modal analysis of two carriages, obtaining free modal frequencies and shapes in the first eight grades for making evaluation of dynamic performance of the carriages. By comparing the quasi static rollover threshold of dump truck at full load and overload, illustrating the overloading dump truck can cause great harm to road safety.Then, lightweight design is made on the rectangular carriage by size optimization method. Defining steel board thickness of each component as design variables, the optimization target is rectangular carriage’s minimum weight. Making sure the rectangular carriage strength and stiffness meeting the requirement by setting the optimization constraints. Obtaining the TY-2rectangular carriage, the TY-2rectangular carriage weight is reduced by16.5%.The result proves that the lightweight design effect good.Finally, aiming at the existing defects of the U type carriage structure, it’s redesigned by topography optimization method in OptiStruct. Selecting a better U type carriage section based on the result of shape optimization, and building the optimization model for topography optimization. After adjustment of the optimization results, obtaining the redesigned U type carriage. The TY-2U type carriage strength and stiffness compared to the original U type carriage are improved obviously.