关键词: 前轴壳；仿真分析；结构优化；可靠性验证

Abstract: As special vehicles integrating heavy-duty transportation and precision operation functions, wheeled cranes impose extremely strict performance requirements on steer front axles, which directly determine the safety, mobility and operation stability of the whole vehicle. Combining simulation and optimization methods, this paper first carries out multi-working-condition simulation analysis on the tailor-welded front axle housing designed for a certain crane to evaluate the structural strength performance, and assesses the design feasibility and potential risks based on the analysis results. Optimization design is then conducted from multiple perspectives including scheme layout, forming process, weight and cost. Finally, sample fabrication, bench tests and vehicle-mounted verification are implemented for the optimized scheme, followed by a 100 000 km reliability road test. It can be concluded that applying simulation analysis and optimization methods in the conceptual design stage of crane front axle housings can not only enhance the reliability and improve the forming process of front axle housings to realize weight reduction and cost cutting, but also greatly boost design efficiency and extend the fatigue life of front axle housings.

Key words: front axle housing; simulation analysis; structural optimization; reliability verification