weight optimization of drill steel support in front of the
TRANSCRIPT
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Weight Optimization of drill steel support in front of the Telescopic Boom of
Face Drilling Machine
Joseph Junior
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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
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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
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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
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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
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Method
1. 1.New Material
2. Topology Optimization
3. Evaluate Castability
4. Shape Optimization
5. CAD Model
6. Evaluate Castability
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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
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Topology Optimization
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Design Spaces Considered for analysis
50/52.3 kg
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24 Load Cases Boundary Conditions
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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
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Shrinkage Porosity from Casting Simulation
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Best Result
Wt:10.5 kg
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Best Result
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Design inspired from the optimization results
Wt: 9.5 kg
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Shape Optimization
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Parametric Modelling
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Shape Optimization Results
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Pareto Plot
Volu
me
in m
m3
Fatigue Life
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Selected Design
Wt: 7.72 kg
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Wt: 9.5 kg
New Design
Factors: Robustness, Deformation limits for the attached components.
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Casting Simulation results
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Achieved Results
0
38
Perc
enta
ge M
ass r
educ
tion
100
68
15