Multi-operating-condition adaptability enhancement: Simulation and Experimental Study on the Roof Beam Structure of Hydraulic Support

Abstract: The mechanical properties of the roof beam structure of hydraulic supports directly affect the safety of support. This paper takes the roof beam of ZY14790/15/25D hydraulic support as the research object, establishes a finite element model through ANSYS software, analyzes the stress and deformation laws of the roof beam under three working conditions: symmetric bending, diagonal torsion, and bending-torsion combination, and identifies the weak areas with stress concentration and large deformation of the roof beam under different working conditions. Based on the analysis results, an optimization technology centered on "enhancing structural continuity, optimizing the load-bearing efficiency of ribs, and strengthening local load-resistant capacity" is proposed, and four optimization schemes are constructed. A new roof beam model is established based on the above schemes, and finite element simulation and cyclic loading comparison tests are carried out. The results show that the maximum stress of the optimized roof beam under the three working conditions is reduced by 31.44%, 19.28%, and 27.20% respectively, the stress distribution is more uniform, and the maximum deformation is reduced by 12.91%, 12.26%, and 15.63% respectively. The test shows that the original roof beam fractures after a total of 16,522 cycles, and the fracture position is at the joint of the top plate and the internal reinforcing plate; the optimized roof beam has a weld crack that extends to the base metal after 19,100 cycles. After standardized repair, it continues to complete the remaining cycles and can stably bear the full yield load, meeting the requirements of actual working conditions. This study provides a practical scheme for the structural optimization of the roof beam of hydraulic supports and has reference value for improving the reliability of coal mining equipment. Keywords: FEM; Optimization Design; Hydraulic Support; Top Beam