Multi-body dynamic and finite element modeling of ultra-large dump truck - haul road interactions for machine health and haul road structural integrity

Haul truck capacities have increased due to their economies of scale in large-scale surface mine production systems. Ultra-large trucks impose high dynamic loads on haul roads. The dynamic loads are exacerbated by road surface roughness and truck over-loading. The dynamic forces also subject trucks to high torsional stresses, which affect truck health. Current haul road response models are 2D and use static truckloads for low capacity trucks. Existing 3D models consider the road as a two-layer system. No models capture the truck dynamic effects on haul roads and predict strut pressures during haulage. Lagrangian mechanics was used to formulate the governing equations of the truck-haul road system. The equations were solved in MSC.ADAMS, based on multi-body dynamics, to generate the truck dynamic forces, which were verified and validated using data obtained from an open-pit mine. These forces were used in an FE model developed, verified and validated in ABAQUS to model the response of the haul road to the truck dynamic forces. The road was modeled using an elastoplastic Mohr-Coulomb model. The results showed that the maximum truck tire dynamic forces were 2.86 and 3.02 times the static force at rated payload and 20% over-loading, respectively. The trucks were exposed to torsional stresses that were up to 2.9 times the recommended threshold. Road deformation decreased with increasing layer modulus and increased with increasing payload. This study proposed novel multivariate models for predicting dynamic truck strut pressures. The novel 3D FE model and empirical relations for calculating truck dynamic forces incorporate truck dynamic forces into haul road design. This study forms a basis for designing structurally competent haul roads and improving truck health --Abstract, page iii

Analytical Modelling of Dump Truck Tire Dynamic Response to Haul Road Surface Excitations

Trucks experience excitations during haulage due to road roughness, generating dynamic loads. Current mine haul road design techniques assume static tire loads, ignoring dynamic forces. This paper presents mathematical models for estimating tire dynamic forces on haul roads. Models were solved in Simulink® and RStudio® to generate random road profile (class D) according to ISO 8608, and compute dynamic forces for 59/80R63 tire. Results show that road roughness significantly affects impact forces on roads, with tire dynamic forces (1638.67 kN) ~ 1.6 times static forces (~1025 kN) at rated tire payloads. The method presented gives realistic estimates of tire impact forces, which serves as useful input for haul road design

Multi-Body Dynamic Modelling of Ultra-Large Dump Truck-Haul Road Interactions towards Haul Road Design Integrity

Haul roads are designed to bear dynamic truckloads generated during haulage. Current road design methods consider static truckloads, which are lower than dynamic loads. They are also unreliable for designing roads for ultra-large trucks. This paper introduces a methodology for designing roads using dynamic loads for any haul truck. A 3D rigid multi-body dynamic virtual model of CAT 797F was built, verified and validated in MSC.ADAMS to model truck tire dynamic forces generated during haulage. Maximum dynamic forces were 2.86 times static force at rated payload. Industrial useable models that capture truck dynamics are proposed to improve road structural design

Three-Dimensional Finite Element Modeling of Haul Road Response to Ultra-Large Dump Truck Dynamic Loading

Haul truck capacities have increased due to their economies of scale in large-scale surface mines. These high-capacity trucks impose dynamic loads on haul roads. A previous study estimated the dynamic forces imposed by ultra-large trucks on haul roads to be more than three times the static load. These dynamic forces exacerbate haul road stresses and deformation. Current haul road response models are 2D and use static truckloads for low-capacity trucks. No models capture the ultra-large truck dynamic effects on haul road structural response. This study uses 3D finite element (FE) modeling to compute the haul road response to ultra-large truck dynamic loading. The dynamic forces were modeled using multibody dynamics (MBD) in MSC.ADAMS. These forces were used in an FE model developed, verified, and validated in ABAQUS, to simulate the response of the haul road to the dynamic truck forces. The road was modeled using an elastoplastic Mohr-Coulomb model. The results showed that road deformation decreases with increasing layer modulus and increases with increasing payload. Increasing the base modulus from 100 MPa to 450 MPa reduced the maximum deformation from 258 mm to 62 mm. When the subbase elastic modulus increased from 100 MPa to 500 MPa, the maximum deformation decreased from 160 mm to 84 mm. Increasing the payload from 0 to 120% of the rated load increased the maximum wearing surface deformation from 131 mm to 216 mm. This study forms a basis for designing structurally competent haul roads for improving haulage efficiency and truck and operator health

Three-Dimensional Finite Element Modeling of Haul Road Response to Ultra-Large Dump Truck Dynamic Loading

Haul truck capacities have increased due to their economies of scale in large-scale surface mines. These high-capacity trucks impose dynamic loads on haul roads. A previous study estimated the dynamic forces imposed by ultra-large trucks on haul roads to be more than three times the static load. These dynamic forces exacerbate haul road stresses and deformation. Current haul road response models are 2D and use static truckloads for low-capacity trucks. No models capture the ultra-large truck dynamic effects on haul road structural response. This study uses 3D finite element (FE) modeling to compute the haul road response to ultra-large truck dynamic loading. The dynamic forces were modeled using multibody dynamics (MBD) in MSC.ADAMS. These forces were used in an FE model developed, verified, and validated in ABAQUS, to simulate the response of the haul road to the dynamic truck forces. The road was modeled using an elastoplastic Mohr-Coulomb model. The results showed that road deformation decreases with increasing layer modulus and increases with increasing payload. Increasing the base modulus from 100 MPa to 450 MPa reduced the maximum deformation from 258 mm to 62 mm. When the subbase elastic modulus increased from 100 MPa to 500 MPa, the maximum deformation decreased from 160 mm to 84 mm. Increasing the payload from 0 to 120% of the rated load increased the maximum wearing surface deformation from 131 mm to 216 mm. This study forms a basis for designing structurally competent haul roads for improving haulage efficiency and truck and operator health

Three-Dimensional Finite Element Modeling of Haul Road Response to Ultra-Large Dump Truck Dynamic Loading

Haul truck capacities have increased due to their economies of scale in large-scale surface mines. These high-capacity trucks impose dynamic loads on haul roads. A previous study estimated the dynamic forces imposed by ultra-large trucks on haul roads to be more than three times the static load. These dynamic forces exacerbate haul road stresses and deformation. Current haul road response models are 2D and use static truckloads for low-capacity trucks. No models capture the ultra-large truck dynamic effects on haul road structural response. This study uses 3D finite element (FE) modeling to compute the haul road response to ultra-large truck dynamic loading. The dynamic forces were modeled using multibody dynamics (MBD) in MSC.ADAMS. These forces were used in an FE model developed, verified, and validated in ABAQUS, to simulate the response of the haul road to the dynamic truck forces. The road was modeled using an elastoplastic Mohr-Coulomb model. The results showed that road deformation decreases with increasing layer modulus and increases with increasing payload. Increasing the base modulus from 100 MPa to 450 MPa reduced the maximum deformation from 258 mm to 62 mm. When the subbase elastic modulus increased from 100 MPa to 500 MPa, the maximum deformation decreased from 160 mm to 84 mm. Increasing the payload from 0 to 120% of the rated load increased the maximum wearing surface deformation from 131 mm to 216 mm. This study forms a basis for designing structurally competent haul roads for improving haulage efficiency and truck and operator health

Three-Dimensional Finite Element Modeling of Haul Road Response to Ultra-Large Dump Truck Dynamic Loading

Haul truck capacities have increased due to their economies of scale in large-scale surface mines. These high-capacity trucks impose dynamic loads on haul roads. A previous study estimated the dynamic forces imposed by ultra-large trucks on haul roads to be more than three times the static load. These dynamic forces exacerbate haul road stresses and deformation. Current haul road response models are 2D and use static truckloads for low-capacity trucks. No models capture the ultra-large truck dynamic effects on haul road structural response. This study uses 3D finite element (FE) modeling to compute the haul road response to ultra-large truck dynamic loading. The dynamic forces were modeled using multibody dynamics (MBD) in MSC.ADAMS. These forces were used in an FE model developed, verified, and validated in ABAQUS, to simulate the response of the haul road to the dynamic truck forces. The road was modeled using an elastoplastic Mohr-Coulomb model. The results showed that road deformation decreases with increasing layer modulus and increases with increasing payload. Increasing the base modulus from 100 MPa to 450 MPa reduced the maximum deformation from 258 mm to 62 mm. When the subbase elastic modulus increased from 100 MPa to 500 MPa, the maximum deformation decreased from 160 mm to 84 mm. Increasing the payload from 0 to 120% of the rated load increased the maximum wearing surface deformation from 131 mm to 216 mm. This study forms a basis for designing structurally competent haul roads for improving haulage efficiency and truck and operator health