Study on Topology Design and Crashworthiness of Novel Anti-impact Units for Hydraulic Supports

doi:10.3969/j.issn.1004-132X.2026.05.005

Abstract

Abstract:

In order to improve the anti-impact of hydraulic supports， based on the characteristics of non-dimensional parameters governing the crashworthiness of thin-walled structures proposed by authors， a new type of anti-impact unit， namely the window multi-celled structures（WMCS）， was designed by adopting bi-tubular and mixed multi-celled structures. The crashworthiness of anti-impact units with different cross-sectional shapes was systematically investigated by using a combination of experimental tests， simulation analysis and theoretical prediction. The results show that the inner and outer contours of the bi-tubular structures and the number of cells affect the deformation modes of the anti-impact units. As the increase of wall thickness， the energy absorption and initial peak crushing forces of the anti-impact units increase， among which the initial peak crushing forces are highly sensitive. Differently， the specific energy absorption and crushing forces efficiency increase first and then decrease. According to the optimal intersection among deformation modes， force-displacement curves and crashworthiness， the WMCS-C1 with a wall thickness of 5 mm was selected as the anti-impact unit.

Key words: hydraulic support, anti-impact unit, bi-tubular structure, topological configuration, crashworthiness

摘要：

为提高液压支架的抗冲击性能，基于本团队先前提出的量纲一参数支配薄壁结构耐撞性的特征趋势，选取双管结构和混合多胞截面的方式设计了一种新型抗冲单元，即窗型多胞结构（WMCS）。采用试验测试、仿真分析与理论预测相结合的方法系统地分析了不同截面形式下抗冲单元的耐撞性。研究结果表明，双管结构的内外轮廓形式和截面胞数影响着抗冲单元的变形模式。随着壁厚的增大，抗冲单元的总吸能和初始峰值压溃力均增大，其中初始峰值压溃力具有高敏感性。不同地，比吸能和压溃力效率先增大再减小。根据变形模式、力位移曲线以及耐撞性三者之间的最优交集，选取壁厚为5 mm的WMCS-C1作为抗冲单元。

关键词: 液压支架, 抗冲单元, 双管结构, 拓扑布局, 耐撞性

CLC Number:

TD355

ZENG Qingliang, LI Zhaoji, QI Guoqing, LIU Peng, WAN Lirong. Study on Topology Design and Crashworthiness of Novel Anti-impact Units for Hydraulic Supports[J]. China Mechanical Engineering, 2026, 37(5): 1054-1062.

曾庆良, 李兆基, 齐国庆, 刘鹏, 万丽荣. 液压支架新型抗冲单元的拓扑设计及耐撞性研究[J]. 中国机械工程, 2026, 37(5): 1054-1062.

Figures/Tables 20

Fig.1 Failure modes of hydraulic supports

Fig.2 Mechanism of rock burst

Fig.3 Mechanical model of rock strata-hydraulic support under rock burst

Fig.4 Schematic diagram of the impact-resistant column structure

Fig.5 Cross-section of anti-impact units

Tab.1 Size parameters of anti-impact units

外管直径

D/mm

内管边长

L/mm

胞元边长

d/mm

壁厚

T/mm

高度

h/mm

初始峰值

压溃力范围/kN

Fig.6 Finite element model of impact unit

Fig.7 Engineering stress-strain curve of the material

Fig.8 Verification of finite element model

Fig.9 Energy ratio for anti-impact units

Fig.10 Deformation modes of anti-impact units

Fig.11 Force-displacement curves of anti-impact units

Fig.12 Crashworthiness of anti-impact units

Fig.13 Crushing force efficiency of anti-impact units

Fig.14 Force-displacement curves of WMCS-C1 at different wall thicknesses

Fig.15 Crashworthiness of WMCS-C1 at different wall thicknesses

Fig.16 Crushing process of the folding unit

Fig.17 Types of junction elements

Fig.18 Deformation characteristics of different junction elements

Tab.2 Comparison of mean crushing force between theoretical model and numerical simulation

抗冲单元类型	理论F_MCF/kN	模拟F_MCF/kN	误差/%
WMCS-C1	5925.9	5682.1	4.1
WMCS-C2	5369.6	5099.3	5.0
WMCS-C3	5054.8	4708.2	6.9
WMCS-C4	4603.5	4425.6	3.9
WMCS-S1	6290.7	5858.3	6.9
WMCS-S2	5731.9	5347.3	6.7
WMCS-S3	5404.1	4892.5	9.5
WMCS-S4	4929.0	4686.0	4.9
WMCS-H1	6064.2	5817.4	4.1
WMCS-H2	5505.8	4962.7	9.7
WMCS-H3	5179.5	4881.1	5.8
WMCS-H4	4704.8	4541.0	3.5

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