weight optimization of drill steel support in front of the
TRANSCRIPT
Weight Optimization of drill steel support in front of the Telescopic Boom of
Face Drilling Machine
Joseph Junior
Background• Face Drilling Machines• Used for mining and
tunneling purposes. • Usually have long telescopic
booms • Carries powerful and heavy
tools in front of long booms
• Should be as compact as possible
• Desired to have higher flexibility, large coverage area on the drilling face, can drill long holes
Background• Drill Steel Support• Located at the front tip of
boom• Closest component to the
rock wall or drilling face• Applies a forces of 25 kN
against the rock wall through a rubber dowel
• Typically a welded plate design or casted steel
Background
Current Design• 15.34 kg• Welded structure• Young's Modulus 210 GPa• Yield Strength 350-360 MPa• Tensile Strength 470-630 MPa• Poisson’s ratio 0.3
Initial Design Target
• Reduce the weight by 15 %• Select an ADI Material and use it for casting the component
Design Constraints
• Keep the mounting interface as the same as the previous design• Able to mount on the existing machine layout
Method
1. 1.New Material
2. Topology Optimization
3. Evaluate Castability
4. Shape Optimization
5. CAD Model
6. Evaluate Castability
New Material
• Austempered Ductile Iron (NE-GJS-900-8 )
• Young's Modulus 169 GPa• Density 7.1 g/cm3
• Poisson's Ratio 0.27• Yield Strength 600 MPa• Tensile Strength 900 MPa
Topology Optimization
Design Spaces Considered for analysis
50/52.3 kg
24 Load Cases Boundary Conditions
Results from the Selected design space
Vol frac 15%Min Thickness 30mmSymmety XY planeSplit Draw XY plane
Vol frac 20%Min Thickness 30mmSymmety XY planeSplit Draw XY plane
Vol frac 20%Min Thickness 40mmSymmety XY planeSplit Draw XY plane
Vol frac 20%Min Thickness 15mmSymmety XY planeSplit Draw XY plane
Desig Space Weight 43.16 kgNet weight 46.90 kg
Shrinkage Porosity from Casting Simulation
Best Result
Wt:10.5 kg
Best Result
Design inspired from the optimization results
Wt: 9.5 kg
Shape Optimization
Parametric Modelling
Shape Optimization Results
Pareto Plot
Volu
me
in m
m3
Fatigue Life
Selected Design
Wt: 7.72 kg
Wt: 9.5 kg
New Design
Factors: Robustness, Deformation limits for the attached components.
Casting Simulation results
Achieved Results
0
38
Perc
enta
ge M
ass r
educ
tion
100
68
15