Lightweight Design Of The Body Of Dump Truck

With the gradual awareness of environmental protection,the demand for dump trucks is getting higher and higher.In order that customer requirements are satisfied,automotive enterprises take lightweight design as the core technology.At present,dump truck is reduced the quality by the single part.The carriage and frame are studied together in this thesis.Carriage and frame of a dump truck are simulated and optimized with the finite element analysis software.The main contents are as follows:(1)The model of dump truck carriage was established and different working conditions were simulated.A model of dump truck carriage was established by SolidWorks and the static and dynamic working conditions of the carriage were analyzed by ANSYS Workbench.The stress distribution and the cloud diagram of deformation of the carriage under different working conditions were obtained.After the strength and stiffness of the analysis results are evaluated,it is concluded that the working requirements of the dump truck are satisfied.The simulation results are used for reference in optimization.(2)Finite element analysis and fatigue life analysis of dump truck frame.Firstly,full load bending and torsion conditions were simulated and analyzed after modeling.The simulation results are satisfied by the stiffness and strength.Secondly,the modal analysis of the frame was carried out.The result shows that the first natural frequency is 14.5Hz,which is lower than the external incentives.In order to ensure that the frame meets the requirements of stiffness and strength,at the same time,it has certain anti-fatigue characteristics.Finally,the fatigue life of the frame was analyzed by nCode Design-Life software.According to the cloud diagram of fatigue life,the result shows that the minimum fatigue life is3.0?10~6 times,and requirement of the safety life is satisfied.It provides a comparative basis for the later optimization design of dump truck frame(3)Lightweight design of the carriage.The structure optimization of dump truck carriage was carried out by selecting the cross section of U-carriage.At the same time,the static and dynamic analysis result of the optimized carriage shows that the working requirements of the strength and stiffness are satisfied.Finally,the harmonic response analysis of the optimized carriage shows that the first natural frequency is higher than the external excitation.The static and dynamic requirements of the optimized carriage are satisfied.(4)Lightweight design of frame.Two schemes were selected to optimize the frame.Scheme 1:New material high strength steel A610L was selected for dump frame,and plate thickness was optimized according to thin shell theory.Scheme 2:Frame was topology optimized by variable density method.According to the optimization results,the frame was re-modeled and simulated under different conditions.The stiffness and strength of the design requirements are satisfied by the optimized results.Finally,the fatigue life of the frame was analyzed.The result shows the optimized life of frame is2.083?10~6 which decreases by 30.57%compared with original model life.In this thesis,the overall model of dump truck was established.The car body was optimized by various methods.Under the condition of guaranteeing the normal operation of dump truck,requirement of fatigue life is satisfied and the mass of the truck is decreased.After carriage and frame of dump truck were optimized,the mass decreases by 8.397%and 9.465%,respectively.The result of optimization is remarkable.The weight of dump truck is reduced and carriage capacity is improved by the methods in this thesis.Meanwhile,the problems of high exhaust emission and low fuel utilization of dump trucks are solved.It has certain reference value for lightweight research of dump truck in later period.