1、摘要自卸车产品的轻量化设计不仅可以降低自卸车制造企业的生产制造成本，而且能够有效增加自卸车辆本身的载货量，是自卸车产品实现环保、节能、经济、安全的有效途径。而相对于自卸车车辆底盘的轻量化实现难易程度及其轻量化空间，其车厢的的轻量化更易实现，且更加有效。随着科技的不断进步、国外先进理念的不断引入及国内自卸车生产制造企业技术力量的不断壮大，计算机辅助工程（CAE）技术、有限单元法等数值和仿真方法也更加普遍的应用在了自卸车车厢轻量化的设计研究中。但目前各自卸车生产制造企业对自卸车车厢的轻量化优化设计多依据经验性的结论来进行局部的静力学分析来实现，为有效降低车厢质量、实现自卸车产品的轻量化，本文提出了
2、下述方案。首先应用 HyperWorks 软件对某自卸车车厢进行了有限元建模，并分别对其满载时液压油缸升举初始瞬间的静载工况和其动载工况进行了模拟，评价原始车厢在该两种工况下的性能，找出原有车厢强度的冗余及不足，并对其进行了轻量化设计。并据此，提出了两种优化方案：方案一是采用高强度的轻质材料改变原始自卸车车厢各关键零件的厚度，使结构在符合静力学强度要求下达到质量最轻；方案二是通过改变车厢结构，由原矩形车厢结构更换为国外流行的 U 形车厢结构，使其在符合静力学强度要求下达到质量最轻。经过对两种方案的强度分析验证，轻量化设计方案一在不改变原车厢结构的前提下， 以车厢部件的材料和板厚作为设计变量进行
3、静态工况及动态冲击工况的优化设计，在满足设计性能要求的同时，实现车厢减重 16.6。该轻量化方案的实现体现了 CAE 技术在车厢轻量化的重要作用；轻量化设计方案二则在满足设计性能要求的同时，相对于原车厢的减重 35.9%，在满足车厢载重条件要求的前提下相对于轻量化方案一的减重比例为 23.1%。方案的实现也为自卸车车厢的轻量化设计提供了一个可借鉴的方法。关键词：自卸车，轻量化，有限元分析，优化IABSTRACTLightweight design dump truck dump truck product can not only reduce manufacturing costs of p
4、roduction, and can effectively increase the amount of cargo dump the vehicle itself, it is an effective way tipper product realization environmental protection, energy saving, economical and safe. Tipper relative to the vehicle chassis to achieve the degree of difficulty and lightweight lightweight
5、space, the weight of the car easier to implement and more effective. Thus, Tipper car lightweight design in recent years has become a dump truck manufacturers an important research topic. Tipper lightweight car is not simply to reduce the weight of the car itself, but to ensure improved product feat
6、ures, product structure is more reasonable and optimize product costs and investment returns on the basis of a more streamlined and effective to reduce the quality of the car itself. As technology advances, the constant introduction of foreign advanced concept and domestic manufacturing enterprises
7、dump truck technology has grown, computer-aided engineering (CAE) technology, the finite element method and numerical simulation method is also more common applications in self unloading the car lightweight design studies. But each dump truck dump truck manufacturing companies to optimize the cars l
8、ightweight design based on more empirical conclusion to the local static analysis to achieve, to effectively reduce the quality of the car, dump truck products to achieve weight reduction proposed under said program.First applications HyperWorks software for a dump truck compartment of the finite el
9、ement model, and their respective hydraulic lift when loaded with the initial moment of static load conditions and other dynamic load conditions were simulated to evaluate the original car in the two kinds of conditions of performance, redundancy and insufficient to identify the strength of the orig
10、inal car, and its lightweight design. And accordingly proposed two optimization options: Option one is the use of high-strength lightweight materials varying the thickness of the key parts of the original car dumper, so that the structure in line with the request of statics strength to meet quality
11、lightest; the second is through programs change the structure of the car, replace the original rectangular Trains popular abroad, U-shaped structure of the car, to reach the quality inIIIline with static strength requirements under the lightest.After analysis of the intensity of the two schemes veri
12、fication, lightweight design in a car without changing the original structure to the material and thickness of car parts as design variables to optimize the design of static conditions and dynamic impact working conditions, in designed to meet the performance requirements while achieving 16.6% car w
13、eight. Implement the lightweight program reflects the important role of CAE technology in the car lightweight; lightweight design two meet design performance requirements, while 35.9% relative to the weight of the original car, with respect to a weight reduction program weight ratio was 23.1%. In ad
14、dition, U-shaped car has a good bearing, lower center of gravity of the vehicle design, appearance more beautiful, but also for the realization of the program was lightweight dump truck cabin design provides a feasible method.Key words: Dump Truck, Lightweight, FEA, optimization目录V第一章绪论11.1 本课题的研究背景
15、和意义11.2 国内外研究现状31.2.1 国内研究现状31.2.2 国外研究现状41.3 本课题主要研究内容4第二章自卸车车厢有限元建模62.1 车厢轻量化方法分析62.1.1 有限元法概述62.1.2 有限元软件介绍82.2 建立几何模型112.3 建立有限元模型152.3.1 模型简化152.3.2 网格划分及质量检查162.3.3 车厢有限元模型172.4 本章小结18第三章自卸车原车厢有限元分析193.1 确定分析工况193.2 强度校核理论193.3 各工况有限元分析结果203.3.1 静载工况203.3.2 动载工况263.4 本章小结32第四章自卸车车厢轻量化设计334.1 高
16、强度板替代的轻量化方案334.1.1 高强度板替代方法334.1.2 静载工况344.1.3 动载工况394.1.4 优化结果对比434.2 U 形车厢结构替代原矩形车厢结构的轻量化方案444.2.1 分析工况464.2.2 静载工况464.2.3 动载工况514.2.4 优化结果对比564.3 本章小结56第五章总结与展望575.1 全文工作总结575.2 下一步工作展望57参考文献59致谢61第一章绪论1.1 本课题的研究背景和意义近年来，随着国家有关部门关于道路行驶安全性的法规愈加完善及全社会环保意识的逐步增强，国内各执法部门对自卸车超限超载的处罚也愈加严厉。如何能够降低自卸车辆自身重量，以期能够获得更高的载质量并
