This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Crashworthiness Optimization of Hydraulic Excavator Cab Roof Rail and Safety Prediction: Finite Element Analysis and Experimental Validation
Technical Paper
2021-01-0925
ISSN: 0148-7191, e-ISSN: 2688-3627
This content contains downloadable datasets
Annotation ability available
Sector:
Event:
SAE WCX Digital Summit
Language:
English
Abstract
Off-road trucks, tractors and earth-moving machines are at high risk of accidents involving falling objects or rollovers. Therefore, these machines need proper protective structures to protect operators. This study investigates the crashworthiness optimization of a hydraulic excavator cab roof rail based on an improved bi-directional evolutionary structural optimization (BESO) method considering two different load cases (a lateral quasi-static load and an impact load from the top of cab, respectively). In the crashworthiness optimization problem, a weighted summation of external works done by the two different load cases is treated as the objective function while the volume of design domain is treated as the constraint. A mutative weight scheme is proposed to stabilize the optimization and balance the two load cases. Finite element (FE) model is established and two prototypes are fabricated based on the optimal design. Explicit FE analysis is used to predict the performance of roll-over protective structure (ROPS) and falling-object protective structure (FOPS) under standardized laboratory test. The smooth evolution histories of reaction forces demonstrate the effectiveness of mutative weight scheme. The simulation-based test results for the ROPS and FOPS have a close agreement with the experimental test results. The accuracy and efficiency of the FE analysis are high enough to predict the behaviors of ROPS and FOPS under the laboratory tests.
Authors
Topic
Citation
Ma, C., Liu, Z., Duan, Y., and Gao, Y., "Crashworthiness Optimization of Hydraulic Excavator Cab Roof Rail and Safety Prediction: Finite Element Analysis and Experimental Validation," SAE Technical Paper 2021-01-0925, 2021, https://doi.org/10.4271/2021-01-0925.Data Sets - Support Documents
Title | Description | Download |
---|---|---|
Unnamed Dataset 1 | ||
Unnamed Dataset 2 |
Also In
References
- Al-Bassit , L. , Tricot , N. , and Sayegh , S. Falling-Object Protective Structure for Tractors in Service: Prototype Design and Validation Biosystems Engineering 185 76 87 2019 10.1016/j.biosystemseng.2019.03.002
- Christensen , J. , and Christophe , B. Nonlinear Optimization of Vehicle Safety Structures: Modeling of Structures Subjected to Large Deformations Amsterdam, Netherlands Butterworth-Heinemann 2016
- Huang , X. , and Xie , M. Evolutionary Topology Optimization of Continuum Structures 2nd New York Wiley 2010
- Huang , X. , Xie , M. , and Lu , G. Topology Optimization of Energy-Absorbing Structures International Journal of Crashworthiness 12 6 663 675 2007 10.1080/1358826-0701497862
- Li , J. , Guan , Y. , Wang , G. , Wang , G. et al. A Meshless Method for Topology Optimization of Structures Under Multiple Load Cases Structures 25 173 179 2020 10.1016/j.istruc.2020.-03.005
- Kammoun , Z. A Formulation for Multiple Loading Cases in Plastic Topology Design of Continua Comptes Rendus Mécanique 344 10 725 735 2016 10.1016/j.crme.2016.-08.002
- Victoria , M. , Querin , O.M. , and Martí , P. Topology Design for Multiple Loading Conditions of Continuum Structures Using Isolines and Isosurfaces Finite Elements in Analysis and Design 46 3 229 237 2010 10.1016/j.finel.2009.09.003
- Sun , G. , Tan , D. , Lv , X. , Yan , X. et al. Multi-Objective Topology Optimization of a Vehicle Door Using Multiple Material Tailor-Welded Blank (TWB) Technology Advances in Engineering Software 124 10 1 9 2018 10.1016/j.adven-gsoft.2018.06.014
- ISO 3471 2008
- ISO 12117-2 2008
- ISO 10262 1998
- SAE J2194 2009
- OECD Code 4 2012
- Clark , B.J. , Thambiratnam , D.P. , and Perera , N.J. Enhancing the Impact Energy Absorption in Roll Over Protective Structures International Journal of Crashworthiness 13 2 167 183 2008 10.1080/13588260701788427
- ISO 3164 2013
- Karlihski , J. , Rusinski , E. , and Smolnicki , T. cProtective Structures for Construction and Mining Machine Operators Automation in Construction 17 3 232 244 2008 10.1016-/j.autcon.2007.05.008
- Harris , J.R. , Winn , G.L. , Ayers , P.D. , and McKenzie , E.A. Predicting the Performance of Cost-Effective Rollover Protective Structure Designs Safety science 49 8-9 1252 1261 2011 10.1016/j.ssci.2011.04.011
- Alfaro , J.R. , Arana , I. , Arazuri , S. and Jarén , C. Assessing the Safety Provided by SAE J2194 Standard and Code 4 Standard Code for Testing ROPS, Using Finite Element Analysis Biosystems Engineering 105 2 189 197 2010
- Grzegorz , K. , and Witold , O. The numerical Simulation of FOPS and ROPS Tests Using LS-DYNA Mechanika 25 5 383 390 2019 10.5755/j01.mech.25.5.4314
- Khorsandi , F. , Ayers , P.D. , and Truster , T.J. Developing and Evaluating a Finite Element Model for Predicting the Two-Posts Rollover Protective Structure Nonlinear Behaviour Using SAE J2194 Static Test Biosystems Engineering 156 96 107 2017 10.1016/j.biosystemseng.2017.01.010
- Huang , X. , and Xie , Y.M. Convergent and Mesh-Independent Solutions for the Bi-Directional Evolutionary Structural Optimization Method Finite Elements in Analysis & Design 43 14 1039 1049 2007 10.1016/j.finel.2007.06.006
- Pathak , D. , Singh , R.P. , Gaur , S. , and Balu , V. Experimental Investigation of Effects of welding Current and Electrode Angle on Tensile Strength of Shielded Metal Arc Welded Low Carbon Steel Plates Materials Today: Proceedings 2020 10.1016/j.mat-pr. 2020.01.146
- Feng , S. 2007
- ASTM E8/E8M-11 Standard Test Methods for Tension Testing of Metallic Materials 2011
- Palanikumar , P. , Gnanasekaran , N. , Subrahmanya , K. , and Kaliveeran , V. Effect of Sliding Speed and Rise in Temperature at the Contact Interface on Coefficient of Friction During Full Sliding of SS304 Materials Today: Proceedings 27 1996 1999 2019 10.1016/j.matpr.2019.09.046
- Wang , Q. , and Fan , Z. Improvement in Analysis of Quasi-Static Collapse with Ls-Dyna Mechanics in Engineering 25 3 20 23 2003
- Rust , W. , and Schweizerhof , K. Finite Element Limit Load Analysis of Thin-Walled Structures by ANSYS (Implicit), LS-DYNA (Explicit) and in Combination Steel Construction 41 2 227 244 2008 10.1016/S0263-8231(02)00089-7