Abstract: A certain mining vehicle enterprise, in response to the customer's demands for cost reduction, weight reduction, and improvement of fuel economy performance, has decided to attempt to adopt topology optimization technology to conduct lightweight and cost-reducing design for the current batch matching of mining cast front axle housings. Based on benchmarking the initial scheme and performance indicators as well as ensuring the assembly relationship, with the maximum stiffness of the front axle housing as the optimization objective, the structural material path for casting the front axle housing is determined, and the structural scheme design of the front axle is carried out. The newly designed front axle housing scheme, after analysis and verification, iterative optimization, and elimination of local stress concentration, determined the final optimization scheme. The results show that under the premise of stress and deformation being less than the existing scheme, the mass is reduced by 35 kg, and the weight is reduced by 9.6%. The successful application of topology optimization technology in the lightweighting of cast front axle housing is verified through A certain mining vehicle enterprise, in response to the customer's demands for cost reduction, weight reduction, and improvement of fuel economy performance, has decided to attempt to adopt topology optimization technology to conduct lightweight and cost-reducing design for the current batch matching of mining cast front axle housings. Based on benchmarking the initial scheme and performance indicators as well as ensuring the assembly relationship, with the maximum stiffness of the front axle housing as the optimization objective, the structural material path for casting the front axle housing is determined, and the structural scheme design of the front axle is carried out. The newly designed front axle housing scheme, after analysis and verification, iterative optimization, and elimination of local stress concentration, determined the final optimization scheme. The results show that under the premise of stress and deformation being less than the existing scheme, the mass is reduced by 35 kg, and the weight is reduced by 9.6%. The successful application of topology optimization technology in the lightweighting of cast front axle housing is verified through A certain mining vehicle enterprise, in response to the customer's demands for cost reduction, weight reduction, and improvement of fuel economy performance, has decided to attempt to adopt topology optimization technology to conduct lightweight and cost-reducing design for the current batch matching of mining cast front axle housings. Based on benchmarking the initial scheme and performance indicators as well as ensuring the assembly relationship, with the maximum stiffness of the front axle housing as the optimization objective, the structural material path for casting the front axle housing is determined, and the structural scheme design of the front axle is carried out. The newly designed front axle housing scheme, after analysis and verification, iterative optimization, and elimination of local stress concentration, determined the final optimization scheme. The results show that under the premise of stress and deformation being less than the existing scheme, the mass is reduced by 35 kg, and the weight is reduced by 9.6%. The successful application of topology optimization technology in the lightweighting of cast front axle housing is verified through A certain mining vehicle enterprise, in response to the customer's demands for cost reduction, weight reduction, and improvement of fuel economy performance, has decided to attempt to adopt topology optimization technology to conduct lightweight and cost-reducing design for the current batch matching of mining cast front axle housings. Based on benchmarking the initial scheme and performance indicators as well as ensuring the assembly relationship, with the maximum stiffness of the front axle housing as the optimization objective, the structural material path for casting the front axle housing is determined, and the structural scheme design of the front axle is carried out. The newly designed front axle housing scheme, after analysis and verification, iterative optimization, and elimination of local stress concentration, determined the final optimization scheme. The results show that under the premise of stress and deformation being less than the existing scheme, the mass is reduced by 35 kg, and the weight is reduced by 9.6%. The successful application of topology optimization technology in the lightweighting of cast front axle housing is verified through A certain mining vehicle enterprise, in response to the customer's demands for cost reduction, weight reduction, and improvement of fuel economy performance, has decided to attempt to adopt topology optimization technology to conduct lightweight and cost-reducing design for the current batch matching of mining cast front axle housings. Based on benchmarking the initial scheme and performance indicators as well as ensuring the assembly relationship, with the maximum stiffness of the front axle housing as the optimization objective, the structural material path for casting the front axle housing is determined, and the structural scheme design of the front axle is carried out. The newly designed front axle housing scheme, after analysis and verification, iterative optimization, and elimination of local stress concentration, determined the final optimization scheme. The results show that under the premise of stress and deformation being less than the existing scheme, the mass is reduced by 35 kg, and the weight is reduced by 9.6%. The successful application of topology optimization technology in the lightweighting of cast front axle housing is verified through bench fatigue tests and reliability verification in the mining area.

Key words: topology optimization; casting front axis housing; lightweight

摘要： 某矿车企业因客户提出降成本、减质量、提升燃油经济性能等要求，决定尝试采用拓 扑优化技术对当前批量匹配的矿用铸造前轴壳进行轻量化降本设计。在对标初始方案和性能 指标以及保证装配关系的基础上，以前轴壳的刚度最大为优化目标，确定铸造前轴壳的结构 材料路径，并进行前轴的结构方案设计。新设计的前轴壳方案在通过分析验证、迭代优化、 消除局部应力集中后发现，最终优化方案在应力、变形小于现有方案的前提下，质量减轻 35 kg， 减重 9.6%，并通过台架疲劳试验和矿区可靠性验证拓扑优化技术在铸造前轴壳轻量化上的成 功应用。

关键词: 拓扑优化；铸造前轴壳；轻量化