Topology optimization of mining vehicle tyres

Abstract

Tyres that are used on light duty mining vehicles (LDMV’s) are for commercial vehicles that have been designed for higher speeds and used predominantly on-highway tarred road surfaces. Substitute tyres that are more sustainable and meet the criteria for mining environments are not currently attainable for this vehicle class. The objective of this research was to develop a topologically optimal tyre fit for mining conditions. As such, a computer generated topologically optimised tyre that better conforms with the design parameters of a mining vehicle was analysed and proposed using classical mechanics through a model-based systems engineering approach. A commercial tyre with all the constituent geometries and dimensions was modelled using computer aided design (CAD). The inherent vehicle data of vehicle kinematics was used as data inputs and boundary conditions to a finite element model (FEM). The model was then algorithmically analysed and optimised with the embedded software program and tools. The main purpose of topologically optimising the tyre was to reduce driveline stresses and have greater vehicle payload capacity. A proof-of-concept tyre design was developed through this research by substituting currently used pneumatic and foam filled commercial tyres with a topologically optimised tyre generated via a FEA software. The mandate was that such a tyre must conform to the vehicle design parameters of the original equipment manufacturer. The results highlighted that changing the tyre topology would better protect the driveshaft. The obtained results indicated the possibility of meeting the metric requirements of having reduced stresses of driveline components. This included reducing the tyre inertia from 6.15 to 2.28 kg/m2, reducing its mass by approximately 70% and redistributing the stress on the tyre. Furthermore, it is shown that topologically optimizing a tyre can result in a tyre with a very high stiffness and subsequent low deformation (up to 90%) characteristics. These are desirable traits in mining applications.