Abstract

The optimization of mining vehicle rear axle weld joints is a complex procedure. The designs for low-cycle fatigue with peak loads were analyzed using computational models and rig testing. On-road evaluation of high-cycle fatigue was performed with the entire vehicle. The iterative analysis is used in design optimization to minimize design cycle time. In sophisticated fatigue calculations with all affecting factors, FEM is utilized. In fatigue failures using road load data, the present deterministic method yields up to 80% correlations. Some critical failure spots were most likely missed owing to operational variations caused by the randomness and multiaxiality of load transfer in link mechanisms with non-linear elements. The fabricated rear axle housing joints are optimized by comparing damage state estimates using stochastic type and multiaxial equivalent loads obtained using Multibody Simulation. The damage state analysis as MBS input stimulus in FE weld models and bolted designs were compared.

摘要

矿车后桥焊接接头的优化是一个复杂的过程。使用计算模型和钻机测试分析了峰值负载低周疲劳的设计。对整车进行了高周疲劳的道路评估。迭代分析用于设计优化，以最大限度地缩短设计周期时间。在包含所有影响因素的复杂疲劳计算中，使用了有限元法。在使用道路负载数据的疲劳失效中，当前的确定性方法产生高达 80% 的相关性。由于非线性元件连杆机构中载荷传递的随机性和多轴性引起的操作变化，一些关键故障点很可能被遗漏。通过使用随机类型和使用多体仿真获得的多轴等效载荷来比较损坏状态估计，对制造的后桥壳接头进行了优化。对 FE 焊接模型和螺栓设计中 MBS 输入激励的损伤状态分析进行了比较。