Research On Lightweight Design Of Heavy-Duty AGV

Nowadays,the finite element analysis method is one of the most popular ways that is implemented in the field of structural mechanics.Besides,it performs better when used in the engineering practice,for instance: reducing the design period,decreasing the expenditure of the design process and increasing the reliability of the products.This thesis will achieve its goals with the aid of the practical engineering projects,which will analyze a 60 t heavily-loaded AGV with 4 different steps,including the simulation of the welding procedure,finite element analysis,size optimization and topology optimization.First of all,the author will utilize the simulation software called Simufact.welding to analyze the frame rail with varying welding sequence,additionally,compare the effects of various simulation results to reach a conclusion that the welding sequence will influence the welding temperature field,welding deformation and residual stress to some extents.The next step will study the frame by using a FEM software named Hypermesh,which will be separated into the following processes: the model setup,geometry cleanup,extraction of the middle plane,mesh generation and the test of the element quality,material property and the complementary connection technology.All of those will be combined with the actual loading situations of the frame to decide the boundary conditions and the dependent working conditions.In addition,the author,with the FE analysis of the frame,will draw a conclusion that the frame meets the requirement of the strength,the stiffness and the saving of the space and the material.The final step will implement the module called Optistruct to optimize the size and the topology of the frame.While the aim of the size optimization is to obtain the minimum mass,namely,the target function.Besides,the independent variable is realized with the varying thickness of the different parts of the beam.Additionally,the constraint function is accomplished by the stress and the deformation constraint.Building up the size optimization model of the frame so as to make the optimization analysis.Meanwhile,the frame can effectively avoid resonance.Finally,the author could attain a light weight model that meet the requirement.The independent variable of the topology optimization is based on the element density,The target function and the constraint conditions have the same requirement,the author also reach the same result of light weight effect.Therefore,the size and the topology optimization does achieve the efficiency,feasibility,and the reliability of the design of the light weight frame to some extents.Which provide a practical idea on the design of the frame structure optimization.