CN117828946A - Bucket wear resistance evaluation method, device, equipment and storage medium - Google Patents
Bucket wear resistance evaluation method, device, equipment and storage medium Download PDFInfo
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Abstract
The invention provides a method, a device, equipment and a storage medium for evaluating the wear resistance of a bucket, belonging to the field of mechanical engineering, wherein the method comprises the following steps: using an EDEM discrete element simulation model to establish a macroscopic dynamics simulation model of the bucket excavating process, and carrying out abrasion simulation analysis on the single bucket excavating process under different working conditions through the macroscopic dynamics simulation model to obtain a region with the most serious bucket abrasion; constructing a model of the most severely worn area of the bucket under the circulating working condition by using finite element software ABAQUS and UMESHMOTION subroutines, and carrying out wear simulation analysis on the most severely worn area of the bucket; and evaluating the wear resistance of the bucket according to the wear simulation analysis result. According to the invention, the numerical simulation method is adopted to predict the bucket abrasion condition under different working conditions, and a digital model can be established according to the actual working conditions, so that the abrasion degree and the service life predicted value are more in line with the actual situation.
Description
Technical Field
The invention belongs to the field of mechanical engineering, and particularly relates to a method, a device, equipment and a storage medium for evaluating wear resistance of a bucket.
Background
When the bucket of engineering machinery such as a loader, an excavator and the like works under severe working conditions such as mines, quarries, cement stirring stations and the like, the wear plates, the bucket teeth and even the whole bucket body are seriously worn, and the bucket needs to be frequently shut down for maintenance and replacement, so that the working efficiency of the whole machine is seriously affected, and the maintenance cost of products is increased.
At present, the service life of the bucket is predicted by combining a small test block wear test with an actual installation test, but the laboratory wear evaluation and installation test result has larger difference, so that the verification period required by corresponding design improvement is longer. Meanwhile, the installation verification is interfered by various uncertain factors such as operation habits, and the like, so that the testing repeatability is poor, and the wear-resistant service life of the bucket is difficult to accurately judge.
Disclosure of Invention
In order to overcome the defect that the wear-resistant service life of the bucket cannot be accurately judged, the invention provides a bucket wear-resistant performance evaluation method, device, equipment and storage medium. The method comprises the following steps:
establishing a macroscopic dynamics simulation model of the bucket excavating process by using the EDEM discrete element simulation model, and carrying out abrasion simulation analysis on the single bucket excavating process under different working conditions by using the macroscopic dynamics simulation model to obtain a region with the most serious bucket abrasion;
constructing a model of the most severely worn area of the bucket under the circulating working condition by using finite element software ABAQUS and UMESHMOTION subroutines, and carrying out wear simulation analysis on the most severely worn area of the bucket;
and evaluating the wear resistance of the bucket according to the wear simulation analysis result.
Preferably, the EDEM discrete element simulation model is used for establishing a macroscopic dynamics simulation model of the bucket excavation process, and the method comprises the following steps of:
constructing a bucket geometric model;
selecting a first contact model between the bucket and the material and a second contact model between the bucket and the material;
and setting the material properties of the bucket and the materials and the contact parameters of the first contact model and the second contact model.
Preferably, the construction of the most worn area of the bucket using the finite element software ABAQUS and umesoxtion subroutines is performed sequentially according to the steps of creating components, creating attributes, assembling components, creating analysis steps, defining loads, defining boundary conditions, meshing, submitting calculations, and post-processing.
Preferably, the region of the bucket that is most severely worn is the partial bucket cross-sectional area of the model that is worn during the cycle.
Preferably, the materials are arranged and combined in EDEMs into rock particle models of different shapes in the form of spheres of the same size and of different sizes, which are equivalent to geometric bodies of different shapes in Abaqus.
Preferably, the first contact model is a Hertz-Mindlin contact model.
Preferably, the second contact model is a Hertz-Mindlin withArchardWear model.
The invention also provides a bucket wear resistance evaluation device, which comprises:
the abrasion area acquisition module is used for establishing a macroscopic dynamics simulation model of the bucket excavating process by using the EDEM discrete element simulation model, and carrying out abrasion simulation analysis on the single bucket excavating process under different working conditions by using the macroscopic dynamics simulation model to obtain an area with the most serious bucket abrasion;
the simulation analysis module is used for constructing a model of the most severely worn area of the bucket under the circulating working condition by using finite element software ABAQUS and UMESHMOTION subroutines, and carrying out wear simulation analysis on the most severely worn area of the bucket;
and the wear resistance evaluation module is used for evaluating the wear resistance of the bucket according to the wear simulation analysis result.
The invention also provides a computer device comprising a memory and a processor; the memory stores a computer program, and the processor is configured to execute the computer program in the memory to perform the bucket wear performance evaluation method.
The present invention also provides a computer readable storage medium storing a computer program adapted to be loaded by a processor to perform a bucket wear performance evaluation method.
The method, the device, the equipment and the storage medium for evaluating the wear resistance of the bucket have the following beneficial effects:
according to the invention, through simulating the bucket excavating process by using EDEM discrete element software, the stress condition, the contact energy and the abrasion depth of the main part of the bucket are compared and analyzed, and the area with the largest stress and the most serious abrasion on the bucket can be obtained; by further performing wear simulation analysis on the local area with the most serious bucket wear by using ABAQUS software and UMESHMOTION subroutine, a bucket wear resistance evaluation system can be established, so that bucket life prediction can be accurately predicted.
Drawings
In order to more clearly illustrate the embodiments of the present invention and the design thereof, the drawings required for the embodiments will be briefly described below. The drawings in the following description are only some of the embodiments of the present invention and other drawings may be made by those skilled in the art without the exercise of inventive faculty.
FIG. 1 is a flow chart of a bucket wear performance evaluation method according to an embodiment of the present invention;
FIG. 2 is a model of an excavator bucket;
FIG. 3 is a particle model simulating different shapes of material;
FIG. 4 illustrates EDEM particle factory parameter settings for a bucket under different operating conditions;
FIG. 5 is a scaled stacking model of different shapes of materials;
FIG. 6 is a cloud chart of bucket forces under a proportionally stacked mixture condition;
FIG. 7 is a trace element model of a weak area of a bucket under different working conditions;
FIG. 8 is a schematic diagram of a frictional wear analysis position;
FIG. 9 is a view of the reciprocal frictional wear of spherical material disposed on the inner wall of a bucket;
FIG. 10 is a stress diagram;
FIG. 11 is a graph of cross-sectional wear change trend;
fig. 12 is a graph showing the wear rate as a function of the number of wear.
Detailed Description
The present invention will be described in detail below with reference to the drawings and the embodiments, so that those skilled in the art can better understand the technical scheme of the present invention and can implement the same. The following examples are only for more clearly illustrating the technical aspects of the present invention, and are not intended to limit the scope of the present invention.
In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "axial", "radial", "circumferential", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings are merely for convenience in describing the technical solutions of the present invention and to simplify the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and therefore should not be construed as limiting the present invention.
Furthermore, the terms "first," "second," and the like are used for descriptive purposes only and are not to be construed as indicating or implying relative importance. In the description of the present invention, it should be noted that, unless explicitly specified or limited otherwise, the terms "connected," "connected," and "connected" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; may be directly connected or indirectly connected through an intermediate medium. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art according to the specific circumstances. In the description of the present invention, unless otherwise indicated, the meaning of "a plurality" is two or more, and will not be described in detail herein.
Examples
The invention provides a bucket wear resistance evaluation method, which comprises the following steps:
and establishing bucket abrasion models under different working conditions based on a finite element-discrete element (FEM-DEM) coupling method, establishing a macroscopic dynamics simulation model of a bucket excavating process of materials through EDEM discrete element software, performing abrasion simulation analysis on a single bucket excavating process under different working conditions, determining the area with the largest stress and the most serious abrasion on the bucket, establishing a bucket local dangerous area abrasion model under different working conditions by utilizing large-scale general finite element software ABAQUS, and researching bucket abrasion mechanism. The relation between the most serious local abrasion loss and related parameters (normal pressure, tangential sliding distance between the bucket and rock particles; bucket hardness; abrasion factor) in the bucket abrasion process under the condition that the bucket is subjected to repeated abrasion is considered, and a set of accurate abrasion resistance evaluation and service life prediction methods and systems are established, and are particularly shown in figure 1.
Step 1: and establishing a macroscopic dynamics simulation model of the bucket excavating process by using the EDEM discrete element simulation model, and carrying out abrasion simulation analysis on the single bucket excavating process under different working conditions by using the macroscopic dynamics simulation model to obtain the area with the most serious bucket abrasion.
The bucket macroscopic dynamics wear simulation model is established mainly by using EDEM software, and wear simulation analysis is performed.
a. Bucket geometry model creation
The excavator bucket is an important component of the excavator, is directly contacted with materials, and is subjected to serious impact force, extrusion force and friction force in the excavating process. The specific stress process comprises the following steps: when the bucket just contacts with the material, the bucket tip is subjected to larger impact force at a higher speed, and the stress of the bucket teeth changes along with the increasing depth of the excavated material, so that a simplified model is shown in fig. 2. According to the invention, a three-dimensional model of the bucket is established through Catia software, and the model is imported into the EDEM to simulate the excavation process.
b. Selection of a contact model
The invention carries out abrasion simulation analysis on the material excavating process of the excavator bucket. And a Hertz-Mindlin (No Slip) contact model is adopted between materials, and the model can accurately reflect the contact characteristics between materials. The Hertz-Mindlin withArchard Wear model is adopted between the material and the bucket, and Record Relative Wear options are selected, so that the main part where abrasion occurs can be predicted, and the abrasion depth value in the excavating process can be obtained.
c. Setting of contact parameters
The material parameters and contact model parameters used for the subject are set forth in tables 1 and 2:
TABLE 1 Material Property parameters of Material and bucket
TABLE 2 contact parameters of materials and bucket
d. Definition of particle model
The default particle shape in EDEM software is spherical, while in practice the rock shape is varied, and simulating rock with spherical particles alone creates larger errors. In order to have a certain analogy with the actual materials in the aspect of particle shape, the invention adopts the arrangement and combination of spheres with the same size and different sizes to form rock particles with different shapes, and four particle models with different shapes are established as shown in figure 3.
Wherein the particle model in (a) is used to simulate spherical or nearly spherical rock; (b) the particle model in the figure is used to simulate columnar rock; (c) The particle model in the figure is used to simulate a pyramid-shaped rock; the particle model in the (d) plot was used to simulate flat rock.
e. Production of particle plants
Particle factories are used to define the time, location, and manner in which particles are generated during simulation. Whether the particle factory definition is reasonable directly determines whether the required particles can be generated efficiently and rapidly, and further the simulation time is directly influenced. Particle plants in EDEM software are largely divided into two forms, static particle plants and dynamic particle plants. The particle mill must be defined based on geometry, either virtual faces or closed geometry can be used to create the particle mill, and can be created in the EDEM software or imported from outside. The geometry used to create the particle mill is created using an internally created method, and particles are created using a dynamic particle mill. The arrangement of the particle mill is shown in fig. 4.
According to the invention, four different-shape particles are mixed according to different proportions to simulate the excavating process under different working conditions, and the accumulation effect of materials after all particles are generated is shown in fig. 5. Different colors represent different types of materials.
f. The wear hazard zone situation is shown in fig. 6, (a) bucket front force diagram, (b) bucket back force diagram.
Step 2: and constructing a model of the most severely worn area of the bucket under the circulating working condition by using finite element software ABAQUS and UMESHMOTION subroutines, and carrying out wear simulation analysis on the most severely worn area of the bucket.
From the EDEM simulation results, the most worn areas of the bucket during operation are the bottom plate and tooth portions of the bucket. Therefore, there is a need to explore bucket wear mechanisms using ABAQUS software and the umesotidion subroutine, and to perform deeper wear simulations on localized areas where bucket wear is most severe. The modeling analysis flow based on the ABAQUS software has 9 procedures, namely, creating a component, creating an attribute, assembling the component, creating an analysis step, defining a load, defining a boundary condition, meshing, submitting calculation and post-processing. Wherein, 1-7 processes can be collectively called as pretreatment, and correspond to the step 9 of post treatment.
a. Creating a local dangerous area abrasion model of the bucket under different working conditions
The invention establishes a partial dangerous area abrasion model of the bucket under different working conditions, wherein the specific size of the partial dangerous area abrasion model is 100mm multiplied by 40mm, and the unit type is an 8-node reduction integral unit (C3D 8R) as shown in figure 7. The diameter of the material particle projectile is 38mm, the unit type is a 4-node tetrahedron unit (C3D 4) (the model only displays ball material particles, and subsequently, different shape material models can be established according to different working conditions), the material particles and parts are arranged according to corresponding material properties, and the material particles are moved to different positions and impact the friction parts along different angles at a certain relative movement speed. The part grid cells employ reduced integration and hourglass control. In order to ensure the accuracy of the calculation result, a square area with the center of the part of 20mm multiplied by 20mm is selected as a part wear observation area, and grid refinement is carried out on the area. The mesh size in the part abrasion deformation observation area is set to be 0.02mm, and other areas adopt a gradual change mesh division mode to improve the simulation efficiency. In order to reduce the influence of shear wave and expansion wave rebound in the part model on the residual stress result, infinite boundary conditions are set around the model, the unit type is infinite unit (CIN 3D 8) with linear elastic property, and all degrees of freedom of the bottom surface nodes of the part are restrained.
According to the invention, the local dangerous area abrasion model of the bucket is partially extracted according to bucket objects under different working conditions, curvature in the bent part of the bucket and actual bucket wall thickness are reserved, the unit type is an 8-node reduction integral unit (C3D 8R), the diameter of a material particle pellet is 20mm, the unit type is a 4-node tetrahedron unit (C3D 4) (the model only displays ball material particles, different shape material models can be established according to different working conditions in the follow-up process), the material particles and parts are arranged according to corresponding material properties, the degree of freedom of the material particles is set, the movement direction of the material is restricted, the movement form is regulated to be reciprocating movement, the numerical pressure of 20N is applied to the rock-soil material through calculation, and the abrasion amount is extracted for every 5 times of reciprocating abrasion until 50 times of reciprocating abrasion, and the total abrasion is 100 times. And selecting a reciprocating abrasion path as an abrasion observation area, and carrying out grid refinement on the abrasion observation area.
b. Combined UMESHMOTION subroutine
The method comprises the steps of applying a subprogram UMESHMOTION of an Abaqus/Standard module to the model, using the subprogram UMESHMOTION in combination with an ALE adaptive grid technology to control node movement, constructing a model of the most severely worn area on a bucket under a circulating working condition by combining the setting of the ABAQUS model and the subprogram UMESHMOTION, and researching the bucket material wear mechanism and quantifying the influence rule of wear process parameters on the wear amount.
Step 3: and establishing a bucket wear resistance evaluation system according to the wear simulation analysis result, and evaluating the bucket wear resistance according to the wear simulation analysis result.
And analyzing simulation results of the local dangerous area, and focusing on transverse comparison when different models are selected to be worn, namely selecting the same position in the different models, and analyzing the wear amount of materials in different shapes. And extracting a wear volume trend chart, obtaining wear data (data such as wear volume, normal wear vector and the like) of more wear times outside a wear experiment according to the provided linear calculation method, and establishing a friction wear database. And comparing the bucket life measurement standards under different working conditions to construct a life evaluation system for the bucket.
The invention also provides a bucket wear resistance evaluation device which comprises a wear area acquisition module, a simulation analysis module and a wear resistance evaluation module. The abrasion area acquisition module is used for establishing a macroscopic dynamics simulation model of the bucket excavating process by using the EDEM discrete element simulation model, and carrying out abrasion simulation analysis on the single bucket excavating process under different working conditions by using the macroscopic dynamics simulation model to obtain an area with the most serious bucket abrasion; the simulation analysis module is used for constructing a model of the most severely worn area of the bucket under the circulating working condition by using finite element software ABAQUS and UMESHMOTION subroutines, and carrying out wear simulation analysis on the most severely worn area of the bucket; the wear resistance evaluation module is used for evaluating the wear resistance of the bucket according to the wear simulation analysis result.
The invention also provides a computer device comprising a memory and a processor; the memory stores a computer program, and the processor is configured to execute the computer program in the memory to perform the bucket wear performance evaluation method.
The present invention also provides a computer readable storage medium storing a computer program adapted to be loaded by a processor to perform a bucket wear performance evaluation method.
According to the invention, the numerical simulation method is adopted to predict the bucket abrasion condition under different working conditions, so that not only can the time and the fund consumption of abrasion evaluation of related products be greatly saved, but also a digital model can be built according to the actual working conditions, so that the abrasion degree and the service life predicted value are more in line with the actual working conditions, and meanwhile, a model which is in line with the actual working conditions is built, so that an important theoretical basis can be provided for the exploration of the abrasion essential mechanism of the related products. The model utilizes EDEM discrete element software to simulate the bucket excavating process, compares and analyzes the stress condition, the contact energy and the abrasion depth of the main part of the bucket, and finds out the parts with the largest stress and the most serious abrasion on the bucket; and the ABAQUS software and UMESHMOTION subprogram are utilized to research the bucket abrasion mechanism, further abrasion simulation analysis is carried out on the local area with the most serious bucket abrasion, an accurate bucket abrasion resistance evaluation system is established, and the time and cost for predicting the bucket service life are saved. And combining the bucket excavation macroscopic dynamics simulation model and the bucket local dangerous area abrasion model under different working conditions, and establishing a bucket size design optimization scheme based on the overall service life improvement of the bucket under different working conditions.
The invention also provides a computer device comprising a memory and a processor; the memory stores a computer program, and the processor is configured to execute the computer program in the memory to perform the bucket wear performance evaluation method.
Example 2
According to the invention, aiming at the wear simulation analysis of the spherical material and the bucket, after a local dangerous area is established by a discrete element method, the friction and wear analysis is carried out, firstly, the local selection of the lower part of the bucket is carried out, the original curvature is reserved, the original wall thickness is reserved as shown in fig. 8, then the spherical material is arranged on the inner wall of the bucket to carry out reciprocating friction and wear, the normal pressure is 20N, the reciprocating wear is carried out for 100 times, as shown in fig. 9, and the related stress diagram data is obtained as shown in fig. 10. And then, after a specific cross section is selected, the abrasion loss of each node under different abrasion times is extracted, and is recorded into a database, so that data such as a cross section abrasion loss change trend chart, an abrasion rate change chart along with the abrasion times and the like are generated, as shown in fig. 11 and 12. The data in the graph can provide references and wear amount predictions under specific working conditions in the research and development process, so that life predictions are obtained.
The above embodiments are merely preferred embodiments of the present invention, the protection scope of the present invention is not limited thereto, and any simple changes or equivalent substitutions of technical solutions that can be obviously obtained by those skilled in the art within the technical scope of the present invention disclosed in the present invention belong to the protection scope of the present invention.
Claims (10)
1. The method for evaluating the wear resistance of the bucket is characterized by comprising the following steps of:
establishing a macroscopic dynamics simulation model of the bucket excavating process by using the EDEM discrete element simulation model, and carrying out abrasion simulation analysis on the single bucket excavating process under different working conditions by using the macroscopic dynamics simulation model to obtain a region with the most serious bucket abrasion;
constructing a model of the most severely worn area of the bucket under the circulating working condition by using finite element software ABAQUS and UMESHMOTION subroutines, and carrying out wear simulation analysis on the most severely worn area of the bucket;
and evaluating the wear resistance of the bucket according to the wear simulation analysis result.
2. The method for evaluating the wear resistance of the bucket according to claim 1, wherein the step of establishing a macroscopic dynamics simulation model of the bucket excavation process using the EDEM discrete element simulation model comprises the steps of:
constructing a bucket geometric model;
selecting a first contact model between the bucket and the material and a second contact model between the bucket and the material;
and setting the material properties of the bucket and the materials and the contact parameters of the first contact model and the second contact model.
3. The method for evaluating the wear resistance of the bucket according to claim 1, wherein the steps of creating a part, creating an attribute, assembling a part, creating an analysis step, defining a load, defining a boundary condition, meshing, submitting a calculation and post-processing are sequentially performed by using finite element software ABAQUS and umesoxtion to construct a model of the region of the bucket where the wear is most serious under the cyclic working condition.
4. The method for evaluating wear resistance of a bucket according to claim 1, wherein the model of the region in which the bucket is most worn is a partial bucket cross-sectional region in a cyclic operation.
5. A bucket wear resistance evaluation method according to claim 1, characterized in that the material is in EDEM in the form of a combination of spherical arrays of the same size and of different sizes constituting rock particle models of different shapes, which are equivalent in Abaqus to geometric bodies of different shapes.
6. The method for evaluating wear resistance of a bucket according to claim 2, wherein the first contact model is a Hertz-Mindlin contact model.
7. The method for evaluating wear resistance of a bucket according to claim 2, wherein the second contact model is a Hertz-Mindlin withArchardWear model.
8. A bucket wear performance evaluation device, characterized by comprising:
the abrasion area acquisition module is used for establishing a macroscopic dynamics simulation model of the bucket excavating process by using the EDEM discrete element simulation model, and carrying out abrasion simulation analysis on the single bucket excavating process under different working conditions by using the macroscopic dynamics simulation model to obtain an area with the most serious bucket abrasion;
the simulation analysis module is used for constructing a model of the most severely worn area of the bucket under the circulating working condition by using finite element software ABAQUS and UMESHMOTION subroutines, and carrying out wear simulation analysis on the most severely worn area of the bucket;
and the wear resistance evaluation module is used for evaluating the wear resistance of the bucket according to the wear simulation analysis result.
9. A computer device comprising a memory and a processor; the memory stores a computer program, the processor being configured to run the computer program in the memory to perform the method of any one of claims 1 to 7.
10. A computer readable storage medium, characterized in that the computer readable storage medium stores a computer program, which is adapted to be loaded by a processor for performing the method of any of claims 1 to 7.
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Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114936436A (en) * | 2022-06-07 | 2022-08-23 | 西南石油大学 | Method for establishing spiral seal wear model of roller bit under high-temperature and dynamic load working conditions |
| CN115587449A (en) * | 2022-10-31 | 2023-01-10 | 浙江工业大学 | EDEM discrete element-based shot blasting machine variable-curvature blade abrasion simulation method |
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| CN114936436A (en) * | 2022-06-07 | 2022-08-23 | 西南石油大学 | Method for establishing spiral seal wear model of roller bit under high-temperature and dynamic load working conditions |
| CN115587449A (en) * | 2022-10-31 | 2023-01-10 | 浙江工业大学 | EDEM discrete element-based shot blasting machine variable-curvature blade abrasion simulation method |
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| 张延强: "WK-75型矿用挖掘机斗齿的磨损分析及结构改进", 《中国优秀硕士学位论文全文数据库工程科技Ⅰ辑》, 15 August 2016 (2016-08-15) * |
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