Vibration Control of the Rail Grinding Vehicle with Abrasive Belt Based on Structural Optimization and Lightweight Design

As a new grinding and maintenance technology,rail belt grinding shows significant advantages in many applications The dynamic characteristics of the rail belt grinding vehicle largely determines its grinding performance and service life.In order to explore the vibration control method of the rail grinding vehicle with abrasive belt,the vibration response changes in structural optimization and lightweight design are respectively analyzed through transient response and random vibration simulations in this paper.Firstly,the transient response simulation analysis of the rail grinding vehicle with abrasive belt is carried out under operating conditions and non-operating conditions.Secondly,the vibration control of the grinding vehicle is implemented by setting vibration isolation elements,optimizing the structure,and increasing damping.Thirdly,in order to further explore the dynamic characteristics of the rail grinding vehicle,the random vibration simulation analysis of the grinding vehicle is carried out under the condition of the horizontal irregularity of the American AAR6 track.Finally,by replacing the Q235 steel frame material with 7075 aluminum alloy and LA43M magnesium alloy,both vibration control and lightweight design can be achieved simultaneously.The results of transient dynamic response analysis show that the acceleration of most positions in the two working conditions exceeds the standard value in GB/T 17426-1998 standard.By optimizing the structure of the grinding vehicle in three ways,the average vibration acceleration of the whole car is reduced by about 55.1%from 15.6 m/s^(2) to 7.0 m/s^(2).The results of random vibration analysis show that the grinding vehicle with Q235 steel frame does not meet the safety conditions of 3σ.By changing frame material,the maximum vibration stress of the vehicle can be reduced from 240.7 MPa to 160.0 MPa and the weight of the grinding vehicle is reduced by about 21.7%from 1500 kg to 1175 kg.The modal analysis results indicate that the vibration control of the grinding vehicle can be realized by optimizing the structure and replacing the materials with lower stiffness under the premise of ensuring the overall strength.The study provides the basis for the development of lightweight,diversified and efficient rail grinding equipment.

Bionic lightweight design of limb leg units for hydraulic quadruped robots by additive manufacturing and topology optimization

Galloping cheetahs,climbing mountain goats,and load hauling horses all show desirable locomotion capability,which motivates the development of quadruped robots.Among various quadruped robots,hydraulically driven quadruped robots show great potential in unstructured environments due to their discrete landing positions and large payloads.As the most critical movement unit of a quadruped robot,the limb leg unit(LLU)directly affects movement speed and reliability,and requires a compact and lightweight design.Inspired by the dexterous skeleton–muscle systems of cheetahs and humans,this paper proposes a highly integrated bionic actuator system for a better dynamic performance of an LLU.We propose that a cylinder barrel with multiple element interfaces and internal smooth channels is realized using metal additive manufacturing,and hybrid lattice structures are introduced into the lightweight design of the piston rod.In addition,additive manufacturing and topology optimization are incorporated to reduce the redundant material of the structural parts of the LLU.The mechanical properties of the actuator system are verified by numerical simulation and experiments,and the power density of the actuators is far greater than that of cheetah muscle.The mass of the optimized LLU is reduced by 24.5%,and the optimized LLU shows better response time performance when given a step signal,and presents a good trajectory tracking ability with the increase in motion frequency.

Lightweight Design of Commercial Vehicle Cab Based on Fatigue Durability

To better improve the lightweight and fatigue durability performance of the tractor cab,a multi-objective lightweight design of the cab was carried out in this study.First,the finite element model of the cab with counterweight loading was established and then confirmed by the physical testing,and use the inertial reliefmethod to obtain stress distribution under unit load.The cab-frame rigid-flexible couplingmulti-body dynamicsmodelwas built by Adams/car software.Taking the cab airbag mount displacement and acceleration signals acquired on the proving ground as the desired signals and obtaining the fatigue analysis load spectrum through Femfat-Lab virtual iteration.The fatigue simulation analysis is performed in nCode based on the Miner linear fatigue cumulative damage theory.Then,with themass and fatigue damage values as the optimization objectives,the bending-torsional stiffness and first-order bending-torsional mode as constraints,the thickness variables are screed based on the sensitivity analysis.The experimental design was carried out using the Optimal Latin hypercube method,and the multi-objective optimal design of the cab was carried out using theKriging approximationmodel fitting and particle swarmalgorithm.The weight of the optimized cab is reduced by 7.8%on the basis of meeting the fatigue durability performance.Finally,a seven-axis road simulation test rig was designed to verify its fatigue durability.The results show the optimized cab can consider both lightweight and durability.

A strategy for lightweight designing of a railway vehicle car body including composite material and dynamic structural optimization

Rolling stock manufacturers are finding structural solutions to reduce power required by the vehicles,and the lightweight design of the car body represents a possible solution.Optimization processes and innovative materials can be combined in order to achieve this goal.In this framework,we propose the redesign and optimization process of the car body roof for a light rail vehicle,introducing a sandwich structure.Bonded joint was used as a fastening system.The project was carried out on a single car of a modern tram platform.This preliminary numerical work was developed in two main steps:redesign of the car body structure and optimization of the innovated system.Objective of the process was the mass reduction of the whole metallic structure,while the constraint condition was imposed on the first frequency of vibration of the system.The effect of introducing a sandwich panel within the roof assembly was evaluated,focusing on the mechanical and dynamic performances of the whole car body.A mass saving of 63%on the optimized components was achieved,corresponding to a 7.6%if compared to the complete car body shell.In addition,a positive increasing of 17.7%on the first frequency of vibration was observed.Encouraging results have been achieved in terms of weight reduction and mechanical behaviour of the innovated car body.

Application of Topology Optimization Technology based on Inspire and 3D Printing in Lightweight Design of Quadrotor UAV

This paper takes the fuselage bracket of the quadrotor UAV as the object,combined with the characteristics of less constraints in the 3D printing process,achieves the optimal structure of the UAV body structure design form,using the inspire topology optimization analysis,with the optimization goal of maximizing the overall stiffness and the optimized structure was checked for strength and verified by 3D printing prototype.The results show that under the premise of meeting the design strength and stiffness requirements,the mass is reduced by 53.29%compared with the original design.The research shows that the application of topology optimization and 3D printing technology to the structural design of UAVs will achieve significant weight reduction effects,providing a feasible way to realize lightweight,complex and integrated design and manufacturing of components.

Lightweight Design and Verification of Gantry Machining Center Crossbeam Based on Structural Bionics

The lightweight and high efficiency of natural structures are the inexhaustible sources for engineering improvements. The goal of the study is to find innovative solutions for mechanical lightweight design through the application of structural bionic approaches. Giant waterlily leaf ribs and cactus stem are investigated for their optimal framework and superior performance. Their structural characteristics are extracted and used in the bio-inspired design of Lin MC6000 gantry machining center crossbeam. By mimicking analogous network structure, the bionic model is established, which has better load-carrying capacity than conventional distribution. Finite Element Method （FEM） is used for numerical simulation. Results show better specific stiffness of the bionic model, which is increased by 17.36%. Finally the scaled models are fabricated by precision casting for static and dynamic tests. The physical experiments are compared to numerical simulation. The results show that the maximum static deformation of the bionic model is reduced by about 16.22%, with 3.31% weight reduction. In addition, the first four natural frequencies are improved obviously. The structural bionic design is a valuable reference for updating conventional mechanical structures with better performance and less material consumption.

Lightweight Design of Automobile Drive Shaft Based on the Characteristics of Low Amplitude Load Strengthening

There are two kinds of internationally recognized approaches in terms of lightweight design.One is based on fatigue accumulated damage theory to achieve better reliability by optimal structural design; another is to use high performance lightweight materials.The former method takes very few considerations on the structural strengthening effects caused by the massive small loads in service.In order to ensure safety,the design is usually conservative,but the strength potential of the component is not fully exerted.In the latter method,cost is the biggest obstacle to lightweight materials in automotive applications.For the purpose of light weighting design on a fuel cell vehicle,the new design method is applied on drive shafts.The method is based on the low amplitude load strengthening characteristics of the material,and allows the stress,corresponding to test load,to enter into the strengthened range of the material.Under this condition,the light weighting design should assure that the reliability of the shaft is not impaired,even maximizes the strength potential of machine part in order to achieve the weight reduction and eventually to reduce the cost.At last,the feasibility of the design is verified by means of strength analysis and modal analysis based on the CAD model of light weighted shaft.The design applies to the load case of half shaft in independent axle,also provides technological reference for the structural lightweight design of vehicles and other machineries.

The Lightweight Design of Low RCS Pylon Based on Structural Bionics

A concept of Specific Structure Efficiency (SSE) was proposed that can be used in the lightweight effect evaluation ofstructures.The main procedures of bionic structure design were introduced systematically.The parameter relationship betweenhollow stem of plant and the minimum weight was deduced in detail.In order to improve SSE of pylons, the structural characteristicsof hollow stem were investigated and extracted.Bionic pylon was designed based on analogous biological structuralcharacteristics.Using finite element method based simulation, the displacements and stresses in the bionic pylon were comparedwith those of the conventional pylon.Results show that the SSE of bionic pylon is improved obviously.Static, dynamic andelectromagnetism tests were carried out on conventional and bionic pylons.The weight, stress, displacement and Radar CrossSection (RCS) of both pylons were measured.Experimental results illustrate that the SSE of bionic pylon is markedly improvedthat specific strength efficiency and specific stiffness efficiency of bionic pylon are increased by 52.9% and 43.6% respectively.The RCS of bionic pylon is reduced significantly.

Lightweight design of 45000r/min spindle using full factorial design and extreme vertices design methods

Factors for determining the spindle size are the shaft diameter, positions of bearing and motor, and entire length of the spindle. Then, it is important to find the assembling of the optimal design variables, which satisfy the stiffimss and rotational speed required to the spindle. A general full factorial design method was used to verify some factors that affect the natural frequency of a spindle. It is verified that the shorter shaft length and bearing span length represent the higher natural frequency, and there are some effects according to the change in the levels of factors. The detailed spindle dimension is determined by applying an EVD method, which can define the optimal bearing position through considering the limiting condition. Based on the estimated regression model, the optimal spindle size and bearing distance that can improve the primary natural frequency are obtained, and the influence of design factors on the natural frequency is also analyzed.

Lightweight design technology of planet carrier for wind turbine gearbox

A finite element model of one-arm planet carrier was built, and influence of structural parameters on strength and stiffness for one-arm planet carrier was analyzed. The stress and deformation of the round structure and the triangle structure for one-arm planet carrier were analyzed and compared. The finite element model of the same specifications arms planet carrier was established, and influence of the connecting slab thickness and input side plate thickness on strength and stiffness for arms planet carrier was analyzed. Strength, stiffness and mass for one-arm and arms planet carrier in the same specifications were analyzed and compared.

Research on Lightweight Design of Automobile Lower Arm Based on Carbon Fiber Materials

Based on the principle of lightweight design, a method of using carbon fiber reinforced composite instead of traditional metal materials to design automobile carrier?can be?proposed. The method uses the equal stiffness design principle of the composite material parts to lay out the design of the carbon fiber parts, including the application of the laying angle and the thickness of the laying layer in design. Through the analysis of the actual working conditions of the lower arm, the stress and boundary conditions are obtained. After the design of the stiffness, the geometrical topology of the lower arm is further optimized. Finally, the lower arm of the carbon fiber not only met the performance requirements,?but also to a certain extent, achieved?the purpose of lightweight.

Biomimetic Lightweight Design of Legged Robot Hydraulic Drive Unit Shell Inspired by Geometric Shape of Fish Bone Rib Structure

The lightweight design of hydraulic quadruped robots,especially the lightweight design of the leg joint Hydraulic Drive Unit(HDU),can improve the robot's response speed,motion speed,endurance,and load capacity.However,the lightweight design of HDU is a huge challenge due to the need for structural strength.This paper is inspired by the geometric shape of fish bones and biomimetic reinforcing ribs on the surface of the HDU shell are designed to increase its strength and reduce its weight.First,a HDU shell with biomimetic fish bone reinforcing ribs structure is proposed.Then,the MATLAB toolbox and ANSYS finite element analysis module are used to optimize the parameters of the biomimetic reinforcing ribs structure and the overall layout of the shell.Finally,the HDU shell is manufactured using additive manufacturing technology,and a performance testing platform is built to conduct dynamic and static performance tests on the designed HDU.The experimental results show that the HDU with biomimetic fish bone reinforcing ribs has excellent dynamic performance and better static performance than the prototype model,and the weight of the shell is reduced by 20%compared to the prototype model.This work has broad application prospects in the lightweight and high-strength design of closed-pressure vessel components.

Lightweight design of peanut sowing machine frame based on finite element analysis

In order to reduce the weight and energy consumption of the whole machine against the heavy mechanical structure and excessive strength redundancy in current small-scale peanut seeders with one ridge and two rows,a finite element model of the frame was established and the static finite element analysis and modal analysis were conducted with ANSYS Workbench.Sensitivity analysis that focuses on the size of intermediate support beams and other components was performed so as to set up a multi-objective optimization model.Then a size optimization and multi-objective optimization collaborative scheme was adopted so that the target was optimized by the Seagull Optimization Algorithm(SOA)to obtain the optimal solution.Based on the results of the finite element analysis,the mechanical structure of the peanut seeder was optimized for lightweight design.Furthermore,response surface plots and static structural analysis were applied for validation.It turned out that the maximum stress of the optimized structure was less than the allowable stress;the weight of the frame reduced by 32.5%after optimization;and the first-order natural frequency did not coincide with the engine input speed or working speed,thus no resonance will occur.Field experiments showed that the qualified rate of row spacing was≥96%when operating at different speeds of different types of seeders;The seeding depth operation performance was stable,with an average qualified rate of seeding depth of≥92%;The performance of the seeders was also stable and reliable due to the lightweight prototype structure.The research outcomes can provide an effective technical reference and theoretical basis for the lightweight design of peanut seeders and for its continuous improvement as well in the future.

Web Layout Design of Large Cavity Structures Based on Topology Optimization

Large cavity structures are widely employed in aerospace engineering, such as thin-walled cylinders, blades andwings. Enhancing performance of aerial vehicles while reducing manufacturing costs and fuel consumptionhas become a focal point for contemporary researchers. Therefore, this paper aims to investigate the topologyoptimization of large cavity structures as a means to enhance their performance, safety, and efficiency. By usingthe variable density method, lightweight design is achieved without compromising structural strength. Theoptimization model considers both concentrated and distributed loads, and utilizes techniques like sensitivityfiltering and projection to obtain a robust optimized configuration. The mechanical properties are checked bycomparing the stress distribution and displacement of the unoptimized and optimized structures under the sameload. The results confirm that the optimized structures exhibit improved mechanical properties, thus offering keyinsights for engineering lightweight, high-strength large cavity structures.

Lightweight Design:Friction‑Based Welding between Metal and Polymer

The heterojunctions between metal and polymer have become the effective ways to produce the lighter,safer and more environmental friendly vehicles for the manufacturing fields of automotive and aerospace.The state-of-the-art frictionbased welding techniques are characterized by low peak temperature,severe plastic deformation,energy efficiency and nonpollution,which can simultaneously realize the mechanical and chemical bonding,improving mechanical performances.In this review,the current progress about friction-based welding techniques is summarized,containing technical development,welding tool design,microstructural characteristic,process optimization,surface modification and joining mechanism.The conclusions and prospects are presented,which focus on the practical implications for the manufacturing sectors and recommendations for further research and development.The purpose of this review is to elucidate the benefits of friction-based welding techniques so that these methods may be better exploited and industrialized.

Multi-Scale Design and Optimization of Composite Material Structure for Heavy-Duty Truck Protection Device

In this paper,to present a lightweight-developed front underrun protection device(FUPD)for heavy-duty trucks,plain weave carbon fiber reinforced plastic(CFRP)is used instead of the original high-strength steel.First,the mechanical and structural properties of plain carbon fiber composite anti-collision beams are comparatively analyzed from a multi-scale perspective.For studying the design capability of carbon fiber composite materials,we investigate the effects of TC-33 carbon fiber diameter(D),fiber yarn width(W)and height(H),and fiber yarn density(N)on the front underrun protective beam of carbon fiber compositematerials.Based on the investigation,a material-structure matching strategy suitable for the front underrun protective beam of heavy-duty trucks is proposed.Next,the composite material structure is optimized by applying size optimization and stack sequence optimization methods to obtain the higher performance carbon fiber composite front underrun protection beam of commercial vehicles.The results show that the fiber yarn height(H)has the greatest influence on the protective beam,and theH1matching scheme for the front underrun protective beamwith a carbon fiber composite structure exhibits superior performance.The proposed method achieves a weight reduction of 55.21% while still meeting regulatory requirements,which demonstrates its remarkable weight reduction effect.

Robust Expected Violation Criterion for Constrained Robust Design Problems and Its Application in Automotive Lightweight Design

Metamodeling techniques are commonly used to replace expensive computer simulations in robust design problems. Due to the discrepancy between the simulation model and metamodel, a robust solution in the infeasible region can be found according to the prediction error in constraint responses. In deterministic optimizations, balancing the predicted constraint and metamodeling uncertainty, expected violation (EV) criterion can be used to explore the design space and add samples to adaptively improve the fitting accuracy of the constraint boundary. However in robust design problems, the predicted error of a robust design constraint cannot be represented by the metamodel prediction uncertainty directly. The conventional EV-based sequential sampling method cannot be used in robust design problems. In this paper, by investigating the effect of metamodeling uncertainty on the robust design responses, an extended robust expected violation (REV) function is proposed to improve the prediction accuracy of the robust design constraints. To validate the benefits of the proposed method, a crashworthiness-based lightweight design example, i.e. a highly nonlinear constrained robust design problem, is given. Results show that the proposed method can mitigate the prediction error in robust constraints and ensure the feasibility of the robust solution.

探测器机械结构静力学分析与轻量化设计

在产品设计过程中,机械结构的静力学分析与轻量化设计对产品的整体质量有着极为重要的影响。对产品的机械结构进行静力学分析可以保证产品有较好稳定性,对产品进行轻量化设计则是提高产品的综合性能,比如在不影响强度的情况下减小产品质量,从而提高产品综合品质。基于此,本文将结合3He管探测器的设计,对其主要部件进行静力学分析,并借助静力学分析结果对探测器的密闭腔体与盖板进行轻量化设计。

应力驱动的2.5D梯度各向异性维诺多孔零件轻量化建模方法

为了提高多孔零件的设计自由度、内部力学性能梯度与实际应力分布的匹配度,提出一种应力驱动的2.5D梯度各向异性维诺多孔零件轻量化设计方法。将零件有限元分析结果分解为应力标量场和应力方向场,通过加权随机采样算法将应力标量场映射为零件设计域内的维诺站点分布,实现零件内部力学性能的梯度分布;将应力方向场映射为二维黎曼流形,提出一种基于胞元择优方向生长策略的各向异性维诺图生成算法,生成胞元沿黎曼流形分布的各向异性维诺图。在此基础上,通过偏置算法、调和距离场和拉伸算法生成光滑的梯度各向异性维诺多孔零件。最后,采用有限元分析、三点弯曲实验等方法将所设计的多孔零件和其他多孔零件进行比较分析。实验结果表明,所提出的梯度各向异性维诺多孔零件建模方法能有效提升零件内部力学性能梯度与实际应力分布的匹配度,降低材料消耗,实现轻量化设计。

堆垛机器人末端执行机构轻量化设计

为了提高堆垛机器人在定制式木工家具生产线的作业效率,设计了一种基于气压驱动的真空吸附式末端执行机构,提出一种针对该机构的两工况多目标轻量化设计方法。首先,校核了两工况下的静动态性能,建立了末端执行机构参数化模型。定义9个设计变量,采用最优拉丁超立方进行试验设计,并对近似模型的精度进行评价,确定径向基神经网络模型作为优化设计的代理模型。然后,以末端执行机构的质量、变形、应力为响应目标,并以执行机构的尺寸为约束进行多目标轻量化设计。最后对优化后的模型加工出样机,进行试验验证。结果表明:优化后末端执行机构在保证静动态特性满足设计要求的前提下,轻量化得到明显改善,质量降幅15.7%。