This thesis investigates the issue of material residue in Volvo Construction Equipment´s A40 dumper by exploring parameters that affect how material gets stuck in the dumper, then later implementing geometrical solutions to reduce this issue. Since full-scale testing and experimenting would be impossible due to costs and time limitations the majority of tests were done through DEM calculations using the DEM simulation software EDEM, with the chosen material for this project being clay. With Volvo aiming to transition to produce only fully electrical dumpers by 2040, current heat-based solutions using exhaust pipes will no longer be viable, thus alternative solutions must be pursued. Initially the project focused on small scale physical experiments, with the aim to create a better understanding how moisture affects clays cohesive and adhesive properties and also be able to use potential findings in later simulations. However, due to scaling and material compaction limitations the project moved on to full scale simulations instead. A realistic baseline simulation of the A40 dumper was developed, modeling cohesive clay material by adjusting different parameters such as particle size, surface energy and plasticity to reflect the correct material behavior. 

Based on a real-world case from a customer of Volvo where wear plates were implemented on an A60 dumper which in turn led to a reduced carryback, several geometrical implementations of plates to the A40 were simulated. The geometrical changes included adding plates to the side walls, front part and the ramp at the rear of the dumper, where each area was simulated separately to identify each plate’s impact on the carryback. Each implementation was evaluated for its impact on the amount and location of carryback, allowing for a systematic study of how geometry affects flow behavior and material detachment during the unloading process. The customer inspired design was further improved using the optimized angles found during the different angle studies, resulting in a significant reduction in carryback mass. It is expected that these changes can improve the already beneficial design of the customer dumper and reinforced the claim that smoother geometry and fewer sharp corners can help to prevent material buildup.  

The results suggest that DEM simulations can serve as a valuable tool for virtually exploring dumper design alternatives, offering insight into carryback behavior and the influence of key parameters. While this method allows for early evaluation of potential geometry changes their alignment with manufacturing constraints, it cannot by itself lead to design optimization. Instead, the findings should be seen as an initial step toward understanding the problem and lays the groundwork for future design improvements. Ultimately, this study contributes to Volvo’s longterm efforts toward fossil-free and efficient construction machinery.