Structural Optimization and Performance Improvement of Three-Wheeled Light Weight Tippers using CAE Method
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Abstract
This study focuses on optimising the design of three-wheeled tippers to improve efficiency and structural integrity. Several design enhancements, such as corrugated sheets and innovative reinforcement systems, were investigated to solve typical concerns in conventional tipper trucks. This study conducted a series of ANSYS simulations to assess the performance of flat and corrugated sheets, demonstrating that corrugated sheets reduce deformation by up to 76% under a 2 kN load. Furthermore, the study compared furring brackets to tubular reinforcements, finding that tubular portions provide greater strength and less deformation due to their higher moments of inertia. Modal analysis of the optimised tipper models revealed stable designs with participation factors below the required 50% threshold, ensuring reliable performance under dynamic loading. The redesigned tipper models showed improved stress distribution and decreased deformation, with the Model-III reducing the deformation from 3.716 mm to 0.629 mm and the von Mises stress from ~160 MPa to 54 MPa when compared to Model-I under normal driving conditions.
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