Topology optimization of the front loader’s working equipment

BACKGROUND: Topological optimization is widely used in aircraft construction and architecture, but is still of limited use in heavy mechanical engineering. At the same time, the metal cutting for production of working bodies, frames and other structures is often carried out by plasma cutters with computer numerical control. This makes it possible to produce flat parts of almost any complexity. Consequently, there is a field for using the topology optimization methods with no need to use additive technologies to create three-dimensional structures. OBJECTIVE: Weight reduction of the structural components of the front loader’s working equipment without loss of rigidity and strength, as compared with traditional designs; exploration of the capabilities of topological optimization for solving this problem. METHODS: The DM-30 loader was used as the base machine. Its work equipment was converted into a set of flat-shaped design volumes, to which the topological optimization methods of the Autodesk Inventor Professional (AIP) software package were applied. As the steel structure of the working equipment is subject to load in different directions during operation, a method of sequential generation of parts’ shapes for each design position and synthesis of all the shapes into a single object was used. The forces acting on the components of the working equipment were determined with dynamic simulation of the design positions for the base machine which made it possible to study the majority of operation cases. RESULTS: As a result, the weight of the front loader was reduced by 36% while sustaining the same strength characteristics. CONCLUSIONS: The proposed method of formation the optimized steel structure is capable of using simple topological optimization modules and obtaining up to 40% less metal-consuming spatial structures.