Multi-body dynamic and finite element modeling of ultra-large dump truck - haul road interactions for machine health and haul road structural integrity
"Haul truck capacities have increased due to their economies of scale in large-scale surface mine production systems. Ultra-large trucks impose high dynamic loads on haul roads. The dynamic loads are exacerbated by road surface roughness and truck over-loading. The dynamic forces also subject trucks to high torsional stresses, which affect truck health. Current haul road response models are 2D and use static truckloads for low capacity trucks. Existing 3D models consider the road as a two-layer system. No models capture the truck dynamic effects on haul roads and predict strut pressures during haulage. Lagrangian mechanics was used to formulate the governing equations of the truck-haul road system. The equations were solved in MSC.ADAMS, based on multi-body dynamics, to generate the truck dynamic forces, which were verified and validated using data obtained from an open-pit mine. These forces were used in an FE model developed, verified and validated in ABAQUS to model the response of the haul road to the truck dynamic forces. The road was modeled using an elastoplastic Mohr-Coulomb model. The results showed that the maximum truck tire dynamic forces were 2.86 and 3.02 times the static force at rated payload and 20% over-loading, respectively. The trucks were exposed to torsional stresses that were up to 2.9 times the recommended threshold. Road deformation decreased with increasing layer modulus and increased with increasing payload. This study proposed novel multivariate models for predicting dynamic truck strut pressures. The novel 3D FE model and empirical relations for calculating truck dynamic forces incorporate truck dynamic forces into haul road design. This study forms a basis for designing structurally competent haul roads and improving truck health"--Abstract, page iii.
Dynamic forces, Finite element modeling, Haul road integrity, Lagrangian mechanics, Multibody dynanamics, Ultra-large mining trucks, Mining Engineering
Missouri University of Science and Technology
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