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

摘要： 轮式起重机是兼具重型运输和精密作业功能的特殊车辆，对转向前轴的性能要求极为 苛刻，直接关系到整车的安全性、机动性和作业稳定性。文章结合仿真及优化方法，先对某 起重机设计的拼焊前轴壳进行多工况的仿真分析，评估结构设计的强度性能，根据分析结果 进行可行性及风险评估，再从方案设计、成型工艺、质量成本等多方面进行优化设计，最后 对优化后的方案进行样件开发、台架试验，装车验证，完成 100 000 km 的可靠性路试。可见， 在起重机前轴壳方案设计阶段，采用仿真分析及优化方法，不仅可以提高前轴壳可靠性，还 可优化前轴壳成型工艺，实现减重降本，对设计效率及前轴壳疲劳寿命的提升具有重要意义。

关键词: 前轴壳；仿真分析；结构优化；可靠性验证