Frame fatigue life assessment of a mining dump truck based on finite element method and multibody dynamic analysis

Aiming at precisely predicting fatigue life for frame of the 220t mining dump truck, a fatigue life analysis method is presented, integrating multibody dynamic analysis and finite element method. The force of main joints at frame are measured from the multibody dynamic model, whose road is restructured based on ISO/TC108/SC2N67. According to GB/T27025-2008, the dynamic stress test of the whole truck is implemented to obtain the peak stress of the mainly forced area, which is compared with the simulated stress. It is found out that the error is allowable so that the accuracy of the finite element model is definitely ensured. The quasi-static stress analysis method is employed to acquire stress influence coefficient under unit load, which is associated with load histories of the frame to get the dangerous stress area. The fatigue life of the frame is calculated on the basis of Palmgren–Miner damage theory. It is turned out that the minimum life area of the frame is located at the frame joints of suspension, which matches the practice.

► Road surface is rebuilt according to the relative standard.
► Accuracy of finite element model is acceptable, compared with tested results.
► High stress area is located at rear of frame.
► The minimum fatigue life is 1.03e6 cycles within suspension joint area.