Innovation in construction machinery castings: Stress distribution and weight reduction design drive performance improvement

In the design process of construction machinery casting, Jinhui used advanced finite element analysis (FEA) technology to perform precise stress analysis on construction machinery casting. This technology simulates the stress, temperature changes and external loads of construction machinery casting during operation to help the design team understand the stress conditions of construction machinery casting under different working conditions. Through this high-precision simulation analysis, Jinhui can identify high-stress areas of construction machinery casting and reduce stress concentration in these areas through optimized design, thereby reducing problems such as cracks and deformation of construction machinery casting caused by stress concentration.
Taking the service provided by Jinhui for the design of a certain excavator bucket casting as an example, the design team first used finite element analysis to simulate the stress distribution of the bucket during operation and found that there was obvious stress concentration at the corners and joints of the bucket. Based on this discovery, Jinhui redesigned the structure of the bucket to make the stress more evenly distributed, reduce high stress points that may cause cracks and fatigue damage, and significantly improve the impact resistance and service life of the bucket.

Jinhui has also conducted a lot of exploration in the optimization of casting structure, especially in the stress distribution design of construction machinery construction machinery casting, and proposed a more reasonable reinforcement and load reduction design. In the design of construction machinery construction machinery casting, it is usually necessary to reinforce the areas with greater stress, while reducing the weight of the parts with less stress. Jinhui has effectively improved the structural stability and strength of the construction machinery casting through rib design and thin-wall structure.
Taking the wheel axle casting of the loader as an example, Jinhui's design team adjusted the rib layout of the wheel axle to increase the thickness of the stress concentration area, while appropriately thinning the parts with less stress, thereby effectively improving the bending and impact resistance of the casting. This design not only improves the strength of the casting, but also effectively avoids stress concentration and fatigue damage caused by unreasonable structure in traditional construction machinery casting.

In the process of casting design, Jinhui pays attention to the optimization of fatigue life. Construction machinery often faces long-term repeated load operation. How to ensure the fatigue resistance of construction machinery casting in long-term use is one of the core requirements of the design. Jinhui evaluates the long-term load response of construction machinery casting in actual working environment through fatigue life analysis of construction machinery casting to ensure that construction machinery casting will not suffer fatigue cracks under repeated loads. In the mining machinery support casting designed for a certain customer, Jinhui optimized the structure of the casting through stress analysis, and further optimized the durability of the casting through simulated fatigue testing. This dual optimization has enabled Jinhui to improve the working stability of the casting and greatly improve the use efficiency of customers.

The weight of the casting of construction machinery directly affects the operating efficiency and fuel consumption of the whole machine. In a high-load and high-intensity working environment, reducing the weight of the casting can improve the overall performance of the mechanical equipment and reduce operating costs. In terms of weight reduction design, Jinhui always adheres to the principle of high strength and lightweight in parallel, and strives to effectively reduce its weight through innovative design while ensuring the performance of the casting.

Jinhui helps customers reduce the unnecessary weight of construction machinery casting through reasonable structural hollowing and local thinning design. In the design of some high-load construction machinery casting, Jinhui accurately calculates the stress area of ​​the casting, hollows the unstressed part, and thins the area with less stress to reduce the overall weight of the casting. Such a design can greatly reduce the weight of the casting, and can also improve the use efficiency of the casting on the basis of ensuring strength.
The track plate casting designed by Jinhui for a large excavator adopts a hollow structure design while ensuring strength, which reduces the weight of the overall casting and improves the maneuverability and fuel efficiency of the excavator. This not only effectively reduces the burden on the machinery, but also improves the operating efficiency and helps customers save a lot of energy consumption.

In order to further reduce the weight of the casting, Jinhui has also made innovations in material selection. By using light alloy materials such as aluminum alloy and magnesium alloy, Jinhui has greatly reduced the overall quality of the casting. On the premise of ensuring the high strength and wear resistance of the casting, Jinhui uses the low density characteristics of light alloy materials to effectively reduce the weight of the casting and improve the performance of the equipment.
Taking the casting designed for the hydraulic system of construction machinery as an example, Jinhui selected aluminum alloy materials with high strength and toughness, successfully achieved the weight reduction of the casting, and at the same time ensured the corrosion resistance and wear resistance of the casting. After using it, customers reported that the casting is light in weight, the durability is greatly improved, the operation is more flexible, and the overall work efficiency of the machinery is greatly improved.

Jinhui also focuses on the internal and external coordinated optimization of construction machinery casting, that is, fully considering the synergy of multiple aspects such as the structure, materials and production process of construction machinery casting in the design. Through in-depth analysis of different material properties and manufacturing processes, Jinhui can better achieve the reduction of casting weight and optimization of performance. In the design of some construction machinery casting, Jinhui combines different production processes, such as 3D printing and precision casting, to provide customers with lighter and higher-performance casting solutions.