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An energy-based fatigue life estimation and optimization of an electric mining dump truck welded frame

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Abstract

In consideration of uncertainties of material fatigue characteristics caused by the dimension size and manufacturing process, an interval strain energy density method for assessing fatigue life of welded structure was presented in this paper. Based on the limit experimental data, the data sequence was expanded by the least squares method to obtain the upper and lower strain energy density life curves of welded joints. Then, the cyclic stress and strain were calculated through the nonlinear finite element analysis for the electric mining dump truck welded frame structure, whose accuracy was testified by the mine road surface test data. The interval fatigue life at possible fatigue failure positions was estimated. In order to extend the life span of the frame and achieve its lightweight, a multi-objectives optimization design was conducted, based on the Kriging surrogate model. The optimal solution was acquired by the non-dominated sorting genetic algorithm. The results showed that the lower bound lifetime of welded frame was bettered from 5.63 years to 14.97 years while its weight reduced by 12.58%.

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Abbreviations

\(\sigma_{{{\text{max}}}}\): :

Maximum tensile stress

\(E\): :

Young’s modulus

\(\overline{\sigma }_{{ \pm {\text{max}}}}\): :

Signed maximum equivalent stress

\(\varepsilon_{ \pm }^{e}\): :

Signed elastic strain

\(\overline{\sigma }_{ \pm }\): :

Signed equivalent stress

\(\overline{\varepsilon }_{ \pm }^{p}\): :

Signed plastic strain

\(\Delta W^{e + }\): :

Elastic strain energy density

\(\Delta W^{p}\): :

Plastic strain energy density

\(\Delta W^{t}\): :

Total strain energy density

\(N_{f}\): :

Fatigue life cycle

\(A\): :

Strain energy density coefficient

\(B\): :

Strain energy density exponent

\(X^{I}\): :

Interval parameter

\(X^{C}\): :

Midpoint value of the interval number

\(X^{W}\): :

Radius value of the interval number

\(y\): :

Dependent variable \(\log_{10} \left( {{\Delta }W^{t} } \right)\)

\(x\): :

Independent variable \(\log_{10} \left( {N_{f} } \right)\)

\(\beta_{1}\): :

Coefficient for the linear term

\(\beta_{2}\): :

Coefficient for the constant term

\(N\): :

Number of equation

\(g\left( x \right)\): :

Unknown function in design space

\(f\left( x \right)\): :

Polynomial approximation function

\(z\left( x \right)\): :

Function representing random process with zero mean value

\(R\): :

Correlation matrix

\(\theta_{k}\): :

Uncertain parameter

\(n_{s}\): :

Number of design variables

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Acknowledgements

This work is supported by the Major Foundation of Hunan Education Department (Grant No.:21A0362) and the Natural Science Foundation of Hunan Province (Grant No.:2020JJ6075 and 2021JJ50042 and 2022JJ50050).

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Authors and Affiliations

  1. Department of Mechanical Engineering, Hunan University of Technology, Zhuzhou, 412007, China

    Chengji Mi, Shiyong Yuan, Rui Ming, Xuewen Xiao & Jiachang Tang

  2. Zhuzhou Gear Co. Ltd, Zhuzhou, 412007, China

    Xianghuan Liu & Xiaolan Hu

  3. Department of Mechanical Engineering, Hunan Technician College of Industry and Commerce, Zhuzhou, 412001, China

    Jidong Liu

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  1. Chengji Mi
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Contributions

CM and XX presented the original interval strain energy density method. SY and RM performed numerical simulation. JT and XL analyzed the data. SY drafted the manuscript. XH and JL conducted on the experimental work. All authors contributed to discussion and modification this manuscript.

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Correspondence to Jiachang Tang.

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Technical Editor: João Marciano Laredo dos Reis.

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Mi, C., Yuan, S., Ming, R. et al. An energy-based fatigue life estimation and optimization of an electric mining dump truck welded frame. J Braz. Soc. Mech. Sci. Eng. 45, 117 (2023). https://doi.org/10.1007/s40430-023-04040-0

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