重型卡车平衡轴支座结构优化

Structure Optimization Design of Heavy Truck Balance-Axle Bracket

针对平衡轴支座在道路试验过程中发生断裂的问题,通过理化分析和铸件解剖,查找出断裂原因为铸造缺陷引起,并对平衡轴支座结构和铸造工艺进行优化设计。采用有限元方法和数值模拟方法分析了该零件在整车不同工况下的应力大小及应力分布情况及铸造工艺的可行性。结果表明,平衡轴支座结构优化后可满足整车强度需求,铸造工艺改进后消除了铸造缺陷。经实车试验,验证了平衡轴支座的可靠性,并对铸件设计流程进行了总结和规范。

Aiming at the problem of breakage of balance-axle bracket for heavy trucks during road test, physical and chemical analysis and dissection for the bracket castings were conducted to find out the reason of breakage. The optimum design of the balance-axle bracket structure and the improvement of casting process were carried out to eliminate the casting defects causing the breakage of balance-axle bracket. The magnitude and distribution of stress in the brackets under different working conditions were analyzed by finite element method, and the improved casting process was simulated by using AnyCasting software. The results show that the optimized structure of the balance-axle bracket meets the strength requirement of the whole vehicle, and the optimized casting process eliminates casting defects. The reliability of the balanced axle bracket castings was verified by the actual vehicle test, and the design process of the castings is summarized and standardized.