基于拓扑优化方法重载变速箱体轻量化设计

摘要

The traditional gear-box housing production follow the principle of conservatism, which caused uneven quality distribution and great weight. In order to get the gear-box housing with reasonable structure and low quality, taking the wheel loaders gearbox housing as the research object, the gearbox housing' s statics character was analyzed by using a combination of theoretical calculation and simulation, and the stress and the deformation were obtained under the maximum load condition. By using Ansys Workbench soft-ware, the modal analysis of the gearbox housing were performed, and the firs 10 nature frequency, modal shapes of the gearbox housing were gotten. Based on the results of the analysis, the structure topology opti-mization was carried out, by using the variable density method and taking the minimum volume as the opti-mization goal, displacement and stress as the constraints. On this base, the optimal design was carried ac-cording the topology optimization cloud. The weight of the optimized gearbox housing is reduced 11. 68%, the biggest deformation is reduced 22. 62%. Analysis results show that,the overall performance of the opti-mized gearbox housing is improved, achieving the dual purpose of lightweight design and improving the reli-ability.%传统变速箱箱体生产遵循保守原则,质量分配不均,自身重量过大.为获得结构合理,质量低的变速箱箱体,以某装载机变速箱箱体为研究对象,采用理论分析计算与仿真相结合的方式对变速箱箱体进行了静力学分析,获得了箱体在最大载荷工况下应力及变形;运用Ansys Workbench软件对箱体进行了模态分析,获得了箱体前10阶的固有频率及振型.基于分析结果采用变密度法,对箱体进行以体积最小为优化目标,以形变和应力为约束条件的结构拓扑优化,在此基础上根据优化后的云图对其进行相对应结构设计.优化后变速箱箱体质量减少11.68%,最大变形量降低20.2%.分析结果表明,优化后的变速箱箱体综合性能得到提高,实现了轻量化设计和提高可靠性的双重目的.