DT HiLoad Truck Tray Design Using Abaqus FEA Simulation
Case study shows how DT HiLoad uses Abaqus FEA to design lightweight, flexible mining truck trays that handle extreme payloads while reducing weight by up to 50%.
DT HiLoad manufactures custom dump truck trays for mining operations worldwide. The company applies nonlinear static finite element analysis in Abaqus to model tray flexibility, stiffness transitions, and fatigue under loads up to 360,000 kg. Simulation results are validated against strain gauge tests and support designs that increase payload capacity while lowering fuel consumption and component wear.
Abaqus FEA enables continuous stiffness modeling to reduce stress concentrations in curved truck trays
Nonlinear static analyses use field data and customer feedback to simulate loads up to 360,000 kg
Weight reduction of up to 50% achieved while maintaining structural integrity under mining conditions
Validation against physical strain gauge testing confirms simulation accuracy for fatigue predictions
Flexible steel plate design dissipates dynamic and static energy better than rigid conventional trays
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