CN115795725A - Hydraulic support design process based on topological optimization and optimization method - Google Patents
Hydraulic support design process based on topological optimization and optimization method Download PDFInfo
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Abstract
The invention provides a hydraulic support design process and an optimization method based on topological optimization, belonging to the technical field of hydraulic support design; the technical problem to be solved is as follows: the improvement of a hydraulic support design process and an optimization method based on topological optimization is provided; the technical scheme for solving the technical problem is as follows: theoretical calculation is carried out based on the classical mechanical strength theory, a top beam and a shield beam of the support are taken as carriers, overall design and structure selection are carried out, a digital prototype model of the hydraulic support is established by modeling software, the size and data of the hydraulic support in the established digital prototype model can be edited and modified, real-time interaction with simulation working conditions is realized, the correctness and reliability of the structure of the hydraulic support are preliminarily verified by the digital prototype model, a model without interference phenomenon is established by adopting a motion simulation and interference check mode, and then a simplified model is established by software for simulation calculation; the invention is applied to the design of the hydraulic support.
Description
Technical Field
The invention provides a hydraulic support design process and an optimization method based on topology optimization, and belongs to the technical field of hydraulic support design.
Background
The coal mine hydraulic support plays a role in supporting the whole coal wall in the coal mining process, a safe working area is supported for coal mining, coal mining is guaranteed to be carried out smoothly and safely, and with the development of computer hardware and the continuous development of software, research and development and optimization of a new product structure are carried out by increasingly utilizing finite element analysis and optimization design in industry, and the coal mine hydraulic support is particularly suitable for structural optimization of large and medium-sized structural components such as the coal mine hydraulic support.
The design of the hydraulic support structure of a new product needs structural optimization design, is mainly based on mechanical analysis, integrates multiple factors such as mathematics, computer science, graphics and the like, and aims to meet the optimization design of the structure of the hydraulic support under specific constraints (such as volume/weight constraint, geometric constraint and the like) with certain targets (such as material consumption minimization, rigidity maximization and the like).
The currently adopted structural Optimization can be generally divided into three different levels, including Size Optimization (Size Optimization), shape Optimization (Shape Optimization) and Topology Optimization (Topology Optimization), which respectively correspond to three different stages in the actual design, wherein the Topology Optimization is a mathematical method for optimizing the distribution of materials in a given area according to a given load condition, constraint conditions and performance indexes; different from the traditional optimization design, the topological optimization does not need to give out the definition of parameters and optimization variables, and can obtain an optimization scheme only by giving out the parameters of the structure, such as model structure, material characteristics, load and percentage of materials to be saved.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention aims to solve the technical problems that: the improvement of a hydraulic support design process and an optimization method based on topology optimization is provided.
In order to solve the technical problems, the invention adopts the technical scheme that: a hydraulic support design process and an optimization method based on topology optimization comprise the following design steps:
step S10: theoretical calculation is carried out based on the classical mechanical strength theory, a top beam and a shield beam are taken as carriers for a support, and overall design and structure selection are carried out:
and (3) obtaining a calculation formula of moment balance based on each force pair O point:
calculation formula of horizontal force balance:
Qf+F 1 sinα 1 +F 2 sina 2 -Psinβ＝0；
the calculation formula of the vertical force balance is as follows:
Pcosβ+F 1 cosα 1 +F 2 cosα 2 -Q＝0；
the top beam is a carrier, and the calculation formula of the balance of each force pair O point to the moment is as follows:
P E t+Pr 2 +QfH o -Qx＝0；
simultaneously solving the equation by the above formula to obtain:
in the formula: f is the friction coefficient between the top beam and the top plate; p is the total working resistance of the upright post; p E The working resistance of the jack is balanced; phi is the instantaneous angle;
respectively calculating the distance between the resultant force point of the top beam and the top covering point, the supporting resultant force and the supporting strength based on the formula, and preliminarily designing a bracket structure based on the data;
step S20: according to the support structure preliminarily designed in the step S10, establishing a digital prototype model of the hydraulic support by using CAD modeling software, wherein the size and data of the hydraulic support in the established digital prototype model can be edited and modified, so that real-time interaction with the CAE simulation working condition is realized;
step S30: preliminarily verifying the correctness and reliability of the hydraulic support structure through a CAD digital prototype model, and establishing a model without interference phenomenon by adopting a motion simulation and interference check mode;
step S40: establishing a simplified model for CAE simulation calculation by using CAD software, wherein the simplified model is consistent with a main body structure of a digital prototype model, and the simplified model needs to be linked with the digital prototype model;
step S50: setting material properties and mechanical properties of parts of a simulation model for each hydraulic support, and performing meshing on the simulation model by using CAE simulation software;
setting simulation conditions by taking GB25974.1 general technical conditions as a standard, setting boundary conditions by using CAE simulation software for simulation, and generating a stress and displacement cloud chart based on a simulation result;
step S60: performing structure optimization design on the hydraulic support by combining simulated stress and displacement cloud pictures, optimizing the structure of a digital prototype model by selecting size, structure and shape optimization methods for main ribs, cover surfaces and top plate parts, and synchronously mapping optimized contents to a simulation model by adjusting size parameters of each part of the digital prototype of the hydraulic support;
step S70: and (3) further optimizing the simulation model result obtained in the step (S60) by using CAE simulation software, and performing topology optimization by adopting a method based on NURBS basis function and SIMP:
for each unit x i Is given a cell density between 0 and 1, i.e. x i ∈[0，1]By the formula
Expression Unit Density x i And Young's modulus E i In which E is min Is the minimum value of the modulus of elasticity (E) min ＞0)，E 0 The modulus of elasticity of a solid cell with a cell density of 1,
where p is a penalty factor;
the calculation formula for topology optimization is as follows:
find x＝(x 1 ，x 2 ，x 3 ，...，x n ) T
Subject to：F＝KU；
0≤x min ≤x i ≤1
in the formula: x is a design variable, and is the relative density of the discrete unit, x i Is the cell density, x i At x min And a maximum value 1, C (x) is an objective function, which represents that the actual flexibility N is the number of design variables in the design domain, U is an overall displacement vector, F is an overall stress (load) vector, K is an overall stiffness matrix, U is a total stiffness matrix i Is a displacement vector of unit i, i is the number of units, k i Is the cell stiffness matrix for cell i, V (x) is the overall volume in the optimization process, V 0 Is the total volume of the design field, VF (VF∈[0,1]) Is a volume ratio constraint;
step S80: and repeating the step S60 and the step S70 for iteration until a product model meeting the actual production and use requirements is generated, and generating a final hydraulic support product structure design drawing after the target is met, so that the digital prototype model and the actually produced hydraulic support tend to have an equal-strength structure.
In step S20, the CAD modeling software specifically uses SolidWorks or NX to build a digital model.
In step S30, a model without interference phenomenon is created, and specifically, the motion state of the support is simulated through motion simulation function software, whether each component is missing or not is checked, whether interference phenomenon exists or not is checked, the length and the allowance stroke of the upright jack are verified, and the mechanical dead point of the side protection jack and the bottom lifting amount of the base are verified.
In step S40, the specific method for establishing the simplified model is as follows:
simplify the hydraulic support structure according to emulation computer performance, remove the structure that does not influence detail spare part, non-major structure of structural strength: the top frame, the protective net, the stop pin seat and the hanging block fill up the welding seams on the outer surface and the inner part of the assembly and welding piece; and further processing the simplified model, removing parts which are not related to working conditions, and combining the simulation model of the assembly welding part into an integral part.
In step S50, the CAE simulation software is specifically HyperWorks, ANSYS, or ABAQUS, and NX or SolidWorks software is used to set the material properties and mechanical properties of the simulation model parts, and the set items include: yield strength, elastic modulus, poisson's ratio;
the meshing specifically uses a second-order tetrahedron and a first-order hexahedron to mesh the structure.
In step S50, the specific method for generating the stress and displacement cloud map is as follows:
a statics analysis mode is adopted, all working conditions of the hydraulic support are subjected to simulation analysis based on the requirement of a main structural member strength test, face-to-face contact is used for direct contact of metal, the friction coefficient is f =0.2, the contact algorithm adopts an augmentation Lagrange method, a rigid unit adopts linear elimination, and the loading mode adopts internal loading;
the calculation formula for the stress at strength is as follows:
stress sigma at the time of selecting the Von-Mises intensity d Should be less than the allowable stress [ sigma ]]。
Compared with the prior art, the invention has the following beneficial effects: the invention provides a hydraulic support design method based on topological optimization, which is mainly based on mechanical analysis and a fourth strength theory and aims at the structural optimization design of a hydraulic support in a product design stage.
Drawings
The invention is further described below with reference to the accompanying drawings:
FIG. 1 is a schematic diagram of a general hydraulic support preliminary design mechanics calculation;
FIG. 2 is a schematic diagram of a hydraulic support digital model established by the invention;
FIG. 3 is a stress cloud for initial input of the stent of the present invention;
FIG. 4 is a cloud view of initial input top beam stress for the inventive bracket;
FIG. 5 is a cloud view of the stress of the top beam after the structural optimization of the present invention;
FIG. 6 is a cloud graph of base stress for initial input of the stent of the present invention;
FIG. 7 is a cloud view of base stress after structural optimization according to the present invention;
FIG. 8 is a stress cloud of a shield beam after structural optimization according to the present invention;
FIG. 9 is a schematic view of a rear structure of a shield beam after topology optimization according to the present invention;
fig. 10 is a stress cloud diagram of a shield beam after topology optimization according to the invention.
Detailed Description
The method comprises the steps of establishing a digital prototype model of the hydraulic support by using CAD modeling software, editing and modifying the size and data of the hydraulic support in the model, further simplifying the digital prototype model by using the CAD modeling software or CAE simulation software, establishing the simulation model, setting the connection relation between parts, setting the material attribute and the mechanical property of each part of the simulation model, performing grid division on the simulation model, setting simulation working conditions and boundary conditions, simulating by using a finite element analysis method, performing structure optimization design on the hydraulic support by combining a finite element analysis simulation result, and generating a final hydraulic support product structure design drawing after further optimizing a product model result to meet a target by using the CAE simulation software, so that the digital prototype model and the actually produced hydraulic support tend to have an equal-strength structure.
The method mainly comprises the steps of designing the fully-mechanized coal mining support equipment by introducing finite element analysis and a topological optimization algorithm, establishing a digital model and a simplified model by common CAD software, establishing a simulation model and dividing grids by CAE software, setting simulation working conditions and boundary conditions, and simulating by adopting a finite element analysis method; by means of shape optimization, size optimization and topology optimization, the digital prototype model and the actually produced hydraulic support tend to be of an equal-strength structure, and meanwhile, the strength and the rigidity of the hydraulic support meet the requirements of a pressure frame test and the actual working condition of a coal mine.
As shown in fig. 1 to 10, the invention specifically provides a hydraulic support structure optimization design method based on topology optimization, which is simple and easy to use, and can be used to achieve the goal of optimization design only by common CAD and CAE software.
In order to introduce the method more popular and easy to understand, the invention is more open and easy to use, and the specific implementation steps can be realized by adopting common three-dimensional CAD software operation as main steps, but the method is not limited to the software and can be completed by other equivalent types of software. The design method of the hydraulic support mainly comprises the following steps:
s10: theoretical calculation is carried out firstly based on the classical mechanical strength theory, and initial overall design and structure selection are carried out. Taking a certain type of support as an example, taking a top beam and a shield beam as carriers as shown in fig. 1:
taking a moment balance equation of each force pair O point:
taking a horizontal force balance equation:
Qf+F 1 sinα 1 +F 2 sinα 2 -Psinβ＝0 (2)
taking a vertical force balance equation:
Pcosβ+F 1 cosα 1 +F 2 cosa 2 -Q＝0 (3)
taking a top beam as a carrier, and taking a moment balance equation by each force pair O point:
P E t+Pr 2 +QfH 0 -Qx＝0 (4)
solving the equations of the joint type (1) - (4) to obtain:
in the formula: f is the friction coefficient between the top beam and the top plate, and f =0.2 is generally selected; p is the total working resistance of the upright post; p E For balancing the working resistance of the jack, the balance compression is positive and the tension is negative; phi is an instantaneous angle as shown in the figure, clockwise is positive, and anticlockwise is negative.
The distance between the resultant force point of the top beam and the top mask point, the supporting resultant force and the supporting strength can be calculated, and the support structure is preliminarily designed.
S20: the accuracy and the reliability of the hydraulic support structure are preliminarily verified through a CAD digital prototype model, a model without interference phenomenon is created in a virtual assembly and interference checking mode, and the accuracy of subsequent steps is prevented from being influenced. As shown in FIG. 2, a digital model can be established by using three-dimensional CAD software such as SolidWorks or NX, the model is generated based on a digital prototype technology, all sizes and data can be edited and modified, and real-time interaction with simulation working conditions can be realized.
S30: the accuracy and the reliability of the hydraulic support structure are preliminarily verified through a CAD digital prototype model, and a model without interference phenomenon is created in a motion simulation and interference check mode, so that the accuracy of the subsequent steps is prevented from being influenced. The motion state of the support can be simulated through SolidWorks or NX motion simulation function, whether each part is missing or not and whether interference phenomenon exists or not are mainly checked, the length and the rich stroke of the upright post jack are verified, and the mechanical dead point of the side wall protection jack and the bottom lifting amount of the base are verified.
S40: and establishing a simplified model for CAE simulation calculation by using CAD software, wherein the simplified model is consistent with the main structure of the digital prototype model, and the model needs to be linked with the digital prototype model so as to repeat the subsequent steps. The simplified model of the step needs to combine the performance of the simulation computer, such as the performance of a CPU (processor) and a GPU (graphics processing unit) of the simulation computer, the CPU with higher dominant frequency is recommended to be selected, the simulation time can be greatly reduced by starting multi-core operation, the efficiency is improved, and the RAM recommends selecting an RECC memory with an error correction function, so that the accuracy of data calculation can be ensured. The hydraulic support structure is simplified according to the performance of a simulation computer, detail parts which do not influence the structural strength and structural members which are not main structures, such as a top frame, a protective net, a pin block, a hanging block and the like, are removed, welding seams on the outer surface and the inner part of a welding assembly are filled, the model is as close as possible to an actual production structure, meanwhile, the model is simplified as possible, and the performance requirement of the computer is met; because of the particularity of the hydraulic support model, the hydraulic support model is mainly changed into a mode with extremely large number but mostly processed by simple plates, the number of polyhedrons is often more than 5000, the requirement of a simulation computer cannot be met, the model can be simplified according to the requirement of working conditions, parts which are not related to the working conditions are removed, the influence of structures such as a guard wall and a telescopic beam on a main body structure can be ignored in an unbalance loading test, and meanwhile, the simulation model of a welding part is combined into a whole part, so that the calculation is simpler and more feasible, and a large amount of time cost is saved. The method is verified by the test of a control group and the information acquired by a pressing frame test bed, the error is not more than 5 percent, and the error is ignored for the mining of the hydraulic support.
The computer configuration selected for this example: CPU is Xeon W2145, GPU is RTX A4000, NVME is 980PRO, RAM (Memory) is RECC 32G.
Step S50: the material properties and the mechanical properties of parts of each simulation model are set by the parts of the hydraulic support, and the simulation models are subjected to grid division by using CAE simulation software. CAE software HyperWorks, ANSYS or ABAQUS can be used, and NX software or SolidWorks can be used for setting the material properties and mechanical properties of the simulation model parts, such as yield strength, elastic modulus and Poisson ratio, for example, Q550 material commonly used for supports, wherein the elastic modulus is 210GPa, the Poisson ratio is 0.3, the yield strength is 550MPa, and the tensile strength is 670MPa; q690 material with an elastic modulus of 210GPa. When the grids are divided, the structure is mainly divided into grids by using a second-order tetrahedron and a first-order hexahedron, for example, the number of the grid of the example bracket ZY2100/37/80D is 223.4 ten thousand, the number of the second-order tetrahedron units (C3D 10) is 176 ten thousand, the number of the first-order hexahedron units (C3D 8) is 8.5 ten thousand, and the calculation precision is 99.6% and 97.5% through a simple grid theory.
Step S50: the setting of simulation conditions takes GB25974.1 general technical conditions as standards, the boundary conditions are set by CAE simulation software for simulation, and a stress and displacement cloud chart is generated based on simulation results. The statics analysis mode is mainly used for analyzing the elasticity of the linear elastic material and the influence of the mass on the structural member of the hydraulic support under the action of static load, and the self-vibration period of the structural member of the hydraulic support is shorter than the load period, so that the inertia effect can be ignored, and the statics analysis mode is suitable for being adopted. According to the requirement of a main structural member strength test of GB 25974.1-2010-hydraulic support universal technical condition for coal mines 5.9.2 section, simulation analysis is carried out on all fifteen working conditions of the hydraulic support, direct metal contact suggests face-to-face contact, the friction coefficient is f =0.2, a contact algorithm suggests an augmented Lagrange method, a rigid unit suggests a linear element, and an internal loading mode is selected.
Because the simulation theory of the method is based on the fourth intensity theory:
Step S60: and (3) performing structure optimization design on the hydraulic support by combining a simulation structure stress cloud chart, optimizing the structure of the digital prototype model by selecting a size, structure and shape optimization method for parts such as the main rib, the cover surface, the top plate and the like, and synchronously mapping the optimized contents to the simulation model by adjusting the size parameters of each part of the digital prototype of the hydraulic support. In the step, as shown in fig. 4, under the working condition of top beam torsion of 1.2 times of working resistance and loading at two ends of the base, according to the stress cloud chart result, it is shown that the hinge position a of the telescopic jack and the top beam, the hinge position B of the side wall jack and the top beam, the hinge position C of the box cover plate at the front end of the column cap and the main rib position C have obvious stress concentration areas at the hinge position D of the top beam and the shield beam, and the yield strength of the Q690 material cannot be met, so that the structure at the position needs to be optimized. Optimizing the model of the digital prototype by using a size optimization and shape optimization method, changing the cover plate at the front end of the top beam cap into an integral bending plate and changing the structure of the box body as shown in FIG. 5; the length of the flitch and the flitch is increased at the hinged part of the top beam and the shield beam. Under the working condition of top beam torsion and loading at two ends of the base, the stress concentration phenomenon of the hinged part of the cover plate and the top cover at the front part of the top beam column cap is obviously improved. As shown in fig. 6, under the base torsion condition of 1.2 times of working resistance, a high stress area exists in the base in the main structural component. According to the stress cloud chart, the main reinforcements and the main reinforcement flitch plates on the front end of the base gap bridge and the two sides of the column nest are all provided with stress concentration areas, the yield strength of the Q690 material cannot be met, and the structure needs to be optimized. The model of the digital prototype is optimized by selecting a size optimization method and a shape optimization method, and as shown in fig. 7, the stress concentration phenomenon of the base is obviously improved under the base torsion working condition.
Step S70: the CAE simulation software is used to further optimize the product model result obtained in step S60, and topology optimization based on NURBS basis function and SIMP method is used as the main means, and the CAE software selected here uses geometric topology optimization and SIMP optimization method. In the field of topology optimization, the NURBS basis function is used for interpolating optimization variables, CAD modeling, CAE analysis and structural topology optimization can be unified, and structural design, analysis and optimization are integrated. A Solid Isotropic Material penalty model SIMP (Solid Isotropic Material with Penalification) is a density-stiffness interpolation model commonly used in topology optimization, the model assumes that the Material density is constant in a unit and takes the constant as a design variable, the Material characteristics are simulated by an exponential function of the unit density so as to simplify the calculation process and improve the calculation efficiency, and the model is the most commonly used Material interpolation method in the density method topology optimization.
In the SIMP method, each unit x i Is given a cell density between 0 and 1, i.e. x i ∈[0，1]By the formula
Can express the unit density x i And Young's modulus E i A relationship between E and min is the minimum value of the modulus of elasticity (E) min >0)，E 0 The modulus of elasticity of a solid cell with a cell density of 1,
and the middle p is a penalty coefficient, the penalty coefficient needs to be selected in combination with calculated amount, the larger the value is, the clearer the optimization result is, but the more the iteration times are, the larger the calculated amount is, and the value is selected to be less than 3 as far as possible in consideration of the specificity of the hydraulic support. The mathematical model of the optimization problem is as follows:
find x＝(x 1 ，x 2 ，x 3 ，...，x n ) T
Subject to:F＝KU；
0≤x mi n≤x i ≤1
wherein x is a design variable and is the relative density of the discrete unit, x i Is cell density, x i Can be in x min And a maximum value of 1, C (x) is an objective function, which means that the actual compliance N is the number of design variables in the design domain, U is the overall displacement vector, F is the overall stress (load) vector, K is the overall stiffness matrix, U is the overall stiffness matrix i Is a displacement vector of unit i, i is the number of units, k i Is the cell stiffness matrix for cell i, V (x) is the overall volume in the optimization process, V 0 Is the total volume of the design field, VF (VF ∈ [0,1 ]]) Is a volume ratio constraint.
In engineering practice, topology Optimization by CAE software, such as Topology Optimization module by NX, can be used to save a lot of computation time. The method is basically the same as the finite element analysis steps, and is different in that global optimization is set, optimization precision and constraint (target value) are set, the particularity of the hydraulic support is considered, the requirement of topology optimization by software is combined with actual engineering experience, and two targets of reducing the volume under the condition of maximum rigidity and meeting the stress value requirement under the condition of minimum volume are respectively solved; when the plate is selected from results, parts such as the top plate and the like with a protection effect or needing to increase the contact area are selected as nonporous structures as possible, main ribs for ensuring the strength and the rigidity are selected as few-hole structures as possible, and manufacturability is considered when the special plate is constructed. As shown in fig. 9, the special gable structure at the rear part of the shield beam is selected from a plurality of optimization results, and belongs to a non-porous structure, so that the weight of the original design is reduced, the stress value of the part is reduced, and the use requirement of the support is met. Meanwhile, by using topological optimization of software, cover plates are reduced in the shield beam box body, holes of the main rib flitch are increased, the weight property of the shield beam is optimized under the condition of unchanged strength by combining the modes of actually changing the shape of the flitch in engineering and the like, and as shown in fig. 10, the optimized shield beam not only solves the problem of local stress concentration of the rear part of the shield beam and a hinge hole on the premise of meeting the rigidity and strength, but also reduces the weight by 0.9t and meets the requirements of actual production and use. The optimized mining hydraulic support passes through a strength test and a fatigue test, can meet the requirements of safe production of mines, and runs well.
Step S80: and repeating the step S60 and the step S70 for iteration until a product model meeting the actual production and use requirements is generated, and generating a final hydraulic support product structure design drawing after the target is met, so that the digital prototype model and the actually produced hydraulic support tend to have an equal-strength structure.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and these modifications or substitutions do not depart from the spirit of the corresponding technical solutions of the embodiments of the present invention.
Claims (6)
1. A hydraulic support design process and an optimization method based on topology optimization are characterized in that: the method comprises the following design steps:
step S10: theoretical calculation is carried out based on the classical mechanical strength theory, a top beam and a shield beam are taken as carriers for the support, and overall design and structure selection are carried out:
and (3) obtaining a calculation formula of moment balance based on each force pair O point:
calculation formula of horizontal force balance:
Qf+F 1 Sinα 1 +F 2 sinα 2 -P sinβ＝0；
the calculation formula of the vertical force balance is as follows:
P cosβ+F 1 cosα 1 +F 2 cosα 2 -Q＝0；
the top beam is a carrier, and a calculation formula of the balance of the forces to the O point is obtained:
P E t+Pr 2 +QfH 0 -Qx＝0；
simultaneously solving the equation by the above formula to obtain:
in the formula: f is the friction coefficient between the top beam and the top plate; p is the total working resistance of the upright post; p is E To balance the working resistance of the jack; phi is an instantaneous angle;
respectively calculating the distance between the resultant force point of the top beam and the top covering point, the supporting resultant force and the supporting strength based on the formula, and preliminarily designing a bracket structure based on the data;
step S20: according to the support structure preliminarily designed in the step S10, establishing a digital prototype model of the hydraulic support by using CAD modeling software, wherein the size and data of the hydraulic support in the established digital prototype model can be edited and modified, so that real-time interaction with the CAE simulation working condition is realized;
step S30: preliminarily verifying the correctness and reliability of the hydraulic support structure through a CAD digital prototype model, and establishing a model without interference phenomenon by adopting a motion simulation and interference check mode;
step S40: establishing a simplified model for CAE simulation calculation by using CAD software, wherein the simplified model is consistent with a main body structure of a digital prototype model, and the simplified model needs to be linked with the digital prototype model;
step S50: setting material properties and mechanical properties of parts of a simulation model for each hydraulic support, and performing meshing on the simulation model by using CAE simulation software;
setting simulation conditions by taking GB25974.1 general technical conditions as a standard, setting boundary conditions by using CAE simulation software for simulation, and generating a stress and displacement cloud chart based on a simulation result;
step S60: carrying out structure optimization design on the hydraulic support by combining simulated stress and displacement cloud pictures, optimizing the structure of a digital prototype model by selecting a size, structure and shape optimization method for main ribs, cover surfaces and top plate parts, and synchronously mapping the optimized contents to a simulation model by adjusting the size parameters of all parts of the digital prototype of the hydraulic support;
step S70: and (3) further optimizing the simulation model result obtained in the step (S60) by using CAE simulation software, and performing topology optimization by adopting a method based on NURBS basis function and SIMP:
for each unit x i Is given a cell density between 0 and 1, i.e. x i ∈[0，1]By the formula
Expression Unit Density x i And Young's modulus E i In which E is min Is the minimum value of the modulus of elasticity (E) min ＞0)，E 0 The modulus of elasticity of a solid cell with a cell density of 1,
where p is a penalty coefficient;
the calculation formula for topology optimization is as follows:
in the formula: x is a design variable, which is the relative density of the cell after discretization, x i Is cell density, x i At x min And a maximum value of 1, C (x) is an objective function, which indicates that the actual flexibility N is the number of design variables in the design domain, U is an overall displacement vector, F is an overall stress (load) vector, K is an overall stiffness matrix, U is a total stiffness matrix i Is a displacement vector of unit i, i is the number of units, k i Is the cell stiffness matrix for cell i, V (x) is the overall volume in the optimization process, V 0 Is the total volume of the design field, CF (VF ∈ [0,1 ]]) Is a volume ratio constraint;
step S80: and repeating the step S60 and the step S70 for iteration until a product model meeting the actual production and use requirements is generated, and generating a final hydraulic support product structure design drawing after the target is met, so that the digital prototype model and the actually produced hydraulic support tend to have an equal-strength structure.
2. The hydraulic support design process and optimization method based on topology optimization according to claim 1, wherein the hydraulic support design process comprises the following steps: in step S20, the CAD modeling software specifically uses SolidWorks or NX to build a digital model.
3. The hydraulic support design process and optimization method based on topology optimization according to claim 2, characterized in that: in step S30, a model without interference phenomenon is created, and specifically, the motion state of the support is simulated through motion simulation function software, whether each component is missing or not is checked, whether interference phenomenon exists or not is checked, the length and the allowance stroke of the upright jack are verified, and the mechanical dead point of the side protection jack and the bottom lifting amount of the base are verified.
4. The hydraulic support design process and optimization method based on topology optimization according to claim 3, wherein the method comprises the following steps: in step S40, the specific method for establishing the simplified model is as follows:
according to the performance of the simulation computer, simplifying the structure of the hydraulic support, and removing detail parts and structural members which do not influence the structural strength and are not of a main body structure: the top frame, the protective net, the stop pin seat and the hanging block fill up the welding seams on the outer surface and the inner part of the assembly welding piece; and further processing the simplified model, removing parts which are not related to working conditions, and combining the simulation model of the assembly welding part into an integral part.
5. The hydraulic support design process and optimization method based on topology optimization according to claim 4, wherein the hydraulic support design process comprises the following steps: in step S50, the CAE simulation software is specifically HyperWorks, ANSYS, or ABAQUS, and NX or SolidWorks software is used to set the material properties and mechanical properties of the simulation model parts, and the set items include: yield strength, elastic modulus, poisson's ratio;
the mesh division specifically uses a second-order tetrahedron and a first-order hexahedron to carry out mesh division on the structure.
6. The hydraulic support design process and optimization method based on topology optimization according to claim 5, wherein the hydraulic support design process comprises the following steps: in step S50, a specific method for generating the stress and displacement cloud map is as follows:
a statics analysis mode is adopted, simulation analysis is carried out on all working conditions of the hydraulic support based on the requirement of a main structural member strength test, face-to-face contact is used for direct contact of metal, the friction coefficient is f =0.2, an augmentation Lagrange method is adopted in a contact algorithm, a linear element is adopted in a rigid unit, and internal loading is adopted in a loading mode;
the calculation formula for the stress at strength is as follows:
stress sigma at the time of selecting the Von-Mises intensity d Should be less than allowable stress [ sigma ]]。
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| CN117828954A (en) * | 2024-03-04 | 2024-04-05 | 质子汽车科技有限公司 | Swing arm fatigue analysis method and system considering contact state and electronic equipment |
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