Journal of Engineering Research and Reports

Trough-making machine is a key special equipment for aqueduct construction, which effectively solves the construction difficulties of long-span, large-volume and high-altitude operation. At present, most trough-making machines are non-standardized equipment designed by empirical methods, leading to material waste and difficulties in controlling structural strength, stiffness and stability. Taking a trough-making machine as the research object, this paper selects the dangerous working condition of full-load pouring under 8-grade wind, calculates wind load and other design loads, establishes a finite element model by ANSYS Parametric Design Language (APDL), and carries out strength and stiffness analysis on its metal structure. On this basis, a zero-order optimization algorithm is used to carry out lightweight optimal design for the main beam, with the minimum volume as the objective function and strength and stiffness as constraints. The results show that the maximum equivalent stress of the whole machine is 216.34 MPa, which is less than the allowable stress of Q355B material; the maximum mid-span deflection of the main beam meets the stiffness limit of L/1000, and all metal structures satisfy the strength and stiffness requirements. After optimization, the mass of the main beam is reduced by about 15.9%, and the overall weight of the trough-making machine is reduced by 5.83%, equivalent to about 54 tons of steel. The optimized structure still meets the design requirements under critical working conditions such as pouring and hole-crossing. The research provides a feasible finite element analysis and structural optimization method for the design of trough-making machines, which can give full play to material performance and realize lightweight design on the premise of ensuring construction safety and pouring quality.