矿用重型自卸车推杆断裂分析与诊断

Analysis and Diagnosis of Pushrod Crack for Mining Heavy Dump Truck

为解决某矿用三轴重型自卸车推杆频繁发生断裂的问题,基于4节点的SHELL63板壳单元和10节点的SOLID92三维实体单元,分别建立车架主体结构和推杆的有限元分析模型。在有限元分析软件ANSYS中分析自卸车在弯曲工况、弯扭组合工况和制动工况下推杆的静态强度和刚度及整车模态振型和模态频率,在MATLAB/SIMULINK环境下以白噪声为基础仿真实际路面谱,完成车架结构的响应谱分析。分析结果表明,有限元分析得出的最大应力位置和推杆在实际使用中出现的异常断裂位置相吻合,找出了该车推杆裂纹过早出现的原因,提出了车架结构改进设计方案,使用效果表明改进方案是有效的。

In order to resolve the problem of pushrod cracks in a three-axes mining heavy dump truck,the FEA model of the major structure of vehicle frame and push rod are established based on 4-node SHELL63 and 10-node SOLID92 elements,respectively.When a heavy dump truck is under the working conditions of a bending load,bending and twisting load,and braking load,the analyses of static strength,pushrod stiffness,and modal shape and modal frequency of vehicle frame are carried through with the help of ANSYS software.The spectrum of the road surface is simulated under a MATLAB/SIMULINK environment based on white noise,and the response spectrum analysis of vehicle frame is completed.The results of the analyses indicate that the location of maximum stress of FEA analysis closely coincide with actual pushrod failure.The reasons for pushrod fatigue cracks appearing in early stages are thus discovered,and methods for the reconstruction of the vehicle frame structure are given,which the reconstruction results proved to be effective.