Analysis Report Station 3 Lifting r4

8/19/2019 Analysis Report Station 3 Lifting r4

1/35

NCSX

Structural Design Analysis Report

Station 3 HoistLift Fixture,

& Lifting Clevis & Lin !in

NCSX"CALC"#$"%%3"%%

April 'ay , %%$

!repare( )y*

___________________________________ Mark Smith, PPPL Mechanical Engineering

!repare( )y*

+++++++++++++++++++++++++++++++++++++++++

Srinivas Avasarala, PPPL Mechanical Engineering

Cece( )y*

________________________________ Art Brooks, PPPL Engineering Analyst

Revie-e( )y*

++++++++++++++++++++++++++++++++++++++++ Tom Brown, PPPL WBS Tooling Constructaility

Revie-e( )y*


Revie-e( )y*

_______________________________________

Mike !iola, PPPL WBS "iel# Perio# Assemly


2/35

Cece( )y*


ii


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!!!L Calculation For.

Calculation $ ___%CS&'CALC'()'**+'** _ ____________ evision $ ______ WP $, i- any

_____________

.E%/'*+01

Pur2ose o- Calculation3 .4e-ine why the calculation is eing 2er-orme#51

e-er to 67ective section within the attache# re2ort5

e-erences .List any source o- #esign in-ormation inclu#ing com2uter 2rogram titles an# revision levels51

e-er to the Metho#s an# e-erences sections o- the attache# re2ort5

Assum2tions .8#enti-y all assum2tions ma#e as 2art o- this calculation51

e-er to the Metho#s sections o- the attache# re2ort5

Calculation .Calculation is either #ocumente# here or attache#51

e-er to the attache# re2ort5

Conclusion .S2eci-y whether or not the 2ur2ose o- the calculation was accom2lishe#51

9es, the 2ur2ose was accom2lishe#5 e-er to the E:ecutive Summary in the attache# re2ort5

Cogni;ant Engineer


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The o--icial #ocument is at htt23>>www5222l5gov>eshis>PPPL _ #ocs5 s html5

The ES?@ an# 8n-rastructure Su22ort 4e2artment maintains the signe# original5

iv

http://www.pppl.gov/eshis/PPPL_docs.shtmlhttp://www.pppl.gov/eshis/PPPL_docs.shtmlhttp://www.pppl.gov/eshis/PPPL_docs.shtml


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0xecutive Su..aryStructural analyses 2rovi#e# estimates -or the stresses antici2ate# #uring 2roo- testing o-

the station + li-t -i:ture, li-ting clevis an# link 2in5 The li-t -i:ture was analy;e# -or three 2roo-

test con-igurations5 The -irst con-iguration, which accounts -or the ma:imum in service loa#, is

-rom li-t 2oint (, an# reuires a 2roo- loa# o- 005 ki2s5 Proo- loa#s o- (05 ki2s an# (D5( ki2s

are reuire# -or li-t 2oints 0 an# + res2ectively5 "inite element analyses show 2eak !on Mises

stresses o- .(5'005)1, 5+, 5() ksi -or li-t 2oints (, 0, an# + with corres2on#ing sa-ety -actors

o- (5, 5F, an# 5) res2ectively5 The #esire was to ma:imi;e the use-ulness o- the li-ting clevis

an# link 2in, y 2roo- testing them at (0G o- the actuatorin5 =sing a H

-illet wel# as s2eci-ie# on the #rawing 2rovi#es a sa-ety -actor o- 55

Structural analyses were 2er-orme# on the Station + hoistli-t -i:ture an# li-ting clevis5

The o7ective was to vali#ate sa-e 2roo- testing con#itions through estimating the antici2ate#

stresses5 The hoistli-t -i:ture was analy;e# -or three 2roo- test con-igurations5 The -irst

con-iguration, which accounts -or the ma:imum in service loa#, is -rom li-t 2oint (, an# reuire#

a 2roo- loa# o- 005 ki2s5 Proo- loa#s o- (05 ki2s an# (D5( ki2s are reuire# -or li-t 2oints 0 an#

+ res2ectively5 "inite element analyses show 2eak !on Mises stresses o- .(5'005)1, 5+, 5()

ksi -or li-t 2oints (, 0, an# + res2ectively5 The 2roo- loa# -or the li-ting clevis is F* ki2s5

Analytical results -or the clevis show the ma:imum stresses are locate# on section 0 an# are3

ma: tensile stress (5D ksi, ma: shear stress F5+ ksi, an# ma: earing stress o- (*50 ksi5 The

wel# loa# is (F0 l->in5

Nee( to* #" Analy7e actuator pin89olt*

a: F0A

v


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9: Analytical

" inclu(e allo-a9les in su..ary/

3" Dra- a conclusion/

;" inclu(e


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5a9le of Contents

!!!L Calculation For.//////////////////////////////////////////////////////////////////////////////////////////////////////////////// ii

0xecutive Su..ary///////////////////////////////////////////////////////////////////////////////////////////////////////////////////// iii

List of Figures///////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////// v

List of 5a9les////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////// v

List of 0?uations//////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////// v29ective///////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////// #

)acgroun(//////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////// #

'eto(s//////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////

Lift Fixture Structural Analysis/////////////////////////////////////////////////////////////////////////////////////////////////// ;

Lift Clevis an( Lin !in Analysis///////////////////////////////////////////////////////////////////////////////////////////////// $

Results Discussion//////////////////////////////////////////////////////////////////////////////////////////////////////////////////////// ##

Su..ary////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////// #3

References///////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////// #;

Appen(ix/////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////// #=

List of Figures///////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////

List of 5a9les////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////List of 0?uations//////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////

)acgroun(//////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////

Lift Fixture Structural Analysis/////////////////////////////////////////////////////////////////////////////////////////////////////

Lift Clevis an( Lin !in Analysis///////////////////////////////////////////////////////////////////////////////////////////////////

Results Discussion////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////

Lifting Clevis 5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555

Link Pin 555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555

Su..ary//////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////

References/////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////

Appen(ix///////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////

List of Figures///////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////iv

List of 5a9les/////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////iv

List of 0?uations///////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////iv

)acgroun(////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////#

Lift Fixture Structural Analysis///////////////////////////////////////////////////////////////////////////////////////////////////

Lift Clevis Analysis////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////@

Su..ary///////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////##

References/////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////#

Appen(ix///////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////#3

vii


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List of Figures

"igure (5 Station +3 Li-t Point Layout in Ma:imum Loa# Con-iguration I(J5555555555555555555555555555555555+

"igure 05 Li-t Point (3 ProMechanica "EM555555555555555555555555555555555555555555555555555555555555555555555555555555555555

"igure +5 Li-t Point (3 ProMechanica "EA esults5555555555555555555555555555555555555555555555555555555555555555555555555 "igure F5 Li-t Point (3 Ansys Workench "EM5555555555555555555555555555555555555555555555555555555555555555555555555555555

"igure 5 Li-t Point (3 Ansys Workench "EA esults5555555555555555555555555555555555555555555555555555555555555555555

"igure 5 Li-t Point 03 Ansys Workench "EM ? Analysis esults55555555555555555555555555555555555555555555555 D"igure D5 Li-t Point +3 Ansys Workench "EM ? Analysis esults55555555555555555555555555555555555555555555555 D

"igure )5 Clevis ? Link Pin Mo#el5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555 )

"igure 5 Station + Li-t Clevis /eometry55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555 "igure (*5 Station + Link Pin /eometry555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555

"igure ((5 Lug ? Pin Connection "ailure Mo#es I)J55555555555555555555555555555555555555555555555555555555555555555555 (*

"igure (05 %on'Linear "EA esults K F* ki2s55555555555555555555555555555555555555555555555555555555555555555555555555555 (0"igure (+5 %on'Linear "EA esults K 005 ki2s55555555555555555555555555555555555555555555555555555555555555555555555555 (0

"igure (F5 ASME e-erence /eometry I0J55555555555555555555555555555555555555555555555555555555555555555555555555555555555 ("igure (5 Pin Shear ? Ben#ing Mo#el5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555 (

"igure (5 Contact Stress Mo#el555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555 (D"igure (D5 Wel# Loa# Mo#el555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555 (D

"igure (5 Station +3 Li-t Point Layout in Ma:imum Loa# Con-iguration I(J55555555555555555555555555555555550

"igure 05 Li-t Point (3 ProMechanica "EM555555555555555555555555555555555555555555555555555555555555555555555555555555555555F"igure +5 Li-t Point (3 ProMechanica "EA esults5555555555555555555555555555555555555555555555555555555555555555555555555F

"igure F5 Li-t Point (3 Ansys Workench "EM5555555555555555555555555555555555555555555555555555555555555555555555555555555

"igure 5 Li-t Point (3 Ansys Workench "EA esults5555555555555555555555555555555555555555555555555555555555555555555"igure 5 Li-t Point 03 Ansys Workench "EM ? Analysis esults55555555555555555555555555555555555555555555555

"igure D5 Li-t Point +3 Ansys Workench "EM ? Analysis esults55555555555555555555555555555555555555555555555

"igure )5 Clevis ? Link Pin Mo#el5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555D"igure 5 Station + Li-t Clevis /eometry55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555)

"igure (*5 Station + Link Pin /eometry555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555)

"igure ((5 Lug ? Pin Connection "ailure Mo#es I)J5555555555555555555555555555555555555555555555555555555555555555555555

"igure (+5 ASME e-erence /eometry I0J55555555555555555555555555555555555555555555555555555555555555555555555555555555555(+"igure (+5 Pin Shear ? Ben#ing Mo#el555555555555555555555555555555555555555555555555555555555555555555555555555555555555555(F

"igure (F5 Contact Stress Mo#el555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555(

"igure (5 Wel# Loa# Mo#el555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555("igure (5 Station +3 Li-t Point Layout in Ma:imum Loa# Con-iguration I(J55555555555555555555555555555555550

"igure 05 Li-t Point (3 ProMechanica "EM555555555555555555555555555555555555555555555555555555555555555555555555555555555555+

"igure +5 Li-t Point (3 ProMechanica "EA esults5555555555555555555555555555555555555555555555555555555555555555555555555F

"igure F5 Li-t Point (3 Ansys Workench "EM5555555555555555555555555555555555555555555555555555555555555555555555555555555F"igure 5 Li-t Point (3 Ansys Workench "EA esults5555555555555555555555555555555555555555555555555555555555555555555

"igure 5 Li-t Point 03 Ansys Workench "EM ? Analysis esults55555555555555555555555555555555555555555555555

"igure D5 Li-t Point +3 Ansys Workench "EM ? Analysis esults55555555555555555555555555555555555555555555555"igure )5 Station + Li-t Clevis CA4 Mo#el555555555555555555555555555555555555555555555555555555555555555555555555555555555555D

"igure 5 Station + Clevis /eometry555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555D

"igure (*5 Clevis Tension Loa#ing an# Section Laels555555555555555555555555555555555555555555555555555555555555555555)"igure ((5 Station + Li-t Clevis "EM5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555(*

viii


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"igure (05 Li-t Clevis Ma:imum !on Mises Stress55555555555555555555555555555555555555555555555555555555555555555555555(*

"igure (+5 ASME e-erence /eometry I0J55555555555555555555555555555555555555555555555555555555555555555555555555555555555(+

List of 5a9lesTale (5 Material Pro2erties5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555 +

Tale 05 Station + Li-t Point Proo- Loa#s, =nit !ectors, ? Sa-ety "actors5555555555555555555555555555555555555 FTale +5 Clevis Allowale Lao#s555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555 (*

Tale F5 Analytical esults Summary55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555 (*

Tale (5 Station + Li-t Point Proo- Loa#s an# =nit !ectors555555555555555555555555555555555555555555555555555555555555+Tale 05 Material Pro2erties5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555+

Tale +5 Material Pro2erties5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555D

Tale F5 Clevis Allowales55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555

Tale 5 Analysis esults Summary55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555(*Tale (5 Station + Li-t Point Proo- Loa#s an# =nit !ectors555555555555555555555555555555555555555555555555555555555555+

Tale 05 Material Pro2erties5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555+

Tale +5 Allowale Loa#s Clevis S( .a>1555555555555555555555555555555555555555555555555555555555555555555555555555555555555555)Tale F5 Allowale Loa#s Clevis S0555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555)

Tale 5 Estimate# Clevis Stresses55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555

List of 0?uations

Euation (5 Allowale Pin Tensile Strength3 I0J e .+'F1555555555555555555555555555555555555555555555555555555555555(

Euation 05 E--ective Wi#th Criteria3 I0J e .+'F155555555555555555555555555555555555555555555555555555555555555555555555 (Euation +5 E--ective Wi#th3 I0J e .+'FD1555555555555555555555555555555555555555555555555555555555555555555555555555555555555 (

Euation F5 Allowale Single Plane "racture Strength3 I0J e .+'F)15555555555555555555555555555555555555555555 (

Euation 5 Allowale 4oule Plane Shear Strength3 I0J e .+'F15555555555555555555555555555555555555555555555(Euation 5 Total Area o- Shear Planes3 I0J e .+'* ? C+'01555555555555555555555555555555555555555555555555555555 (

Euation D5 Allowale Bearing Stress3 I0J e .+'(155555555555555555555555555555555555555555555555555555555555555555555 (

Euation )5 Pin Moment interval Ia J55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555 (

Euation 5 Pin Shear interval I cJ55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555 (Euation (*5 Pin Moment interval I cJ355555555555555555555555555555555555555555555555555555555555555555555555555555555555555 (

Euation ((5 Pin %ormal Stress -rom Ben#ing555555555555555555555555555555555555555555555555555555555555555555555555555555 (

Euation (05 Pin Comine# Stress3 !on Mises I0J555555555555555555555555555555555555555555555555555555555555555555555555 (Euation (+5 Contact Stress @al- Wi#th IJ555555555555555555555555555555555555555555555555555555555555555555555555555555555 (D

Euation (F5 Contact Stress Ma:imum Pressure I J55555555555555555555555555555555555555555555555555555555555555555555 (D

Euation (5 Wel# Loa# IDJ55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555 (DEuation (5 Allowale Pin Tensile Strength3 I0J e .+'F1555555555555555555555555555555555555555555555555555555555555(+

Euation 05 E--ective Wi#th Criteria3 I0J e .+'F155555555555555555555555555555555555555555555555555555555555555555555555(+

Euation +5 E--ective Wi#th3 I0J e .+'FD1555555555555555555555555555555555555555555555555555555555555555555555555555555555555(+

Euation F5 Allowale Single Plane "racture Strength3 I0J e .+'F)15555555555555555555555555555555555555555555(+

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Euation 5 Allowale 4oule Plane Shear Strength3 I0J e .+'F15555555555555555555555555555555555555555555555(+

Euation 5 Total Area o- Shear Planes3 I0J e .+'* ? C+'01555555555555555555555555555555555555555555555555555555(+

Euation D5 Allowale Bearing Stress3 I0J e .+'(155555555555555555555555555555555555555555555555555555555555555555555(+Euation )5 Pin Moment interval Ia J55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555(F

Euation 5 Pin Shear interval I cJ55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555(F

Euation (*5 Pin Moment interval I cJ355555555555555555555555555555555555555555555555555555555555555555555555555555555555555(FEuation ((5 Pin %ormal Stress -rom Ben#ing555555555555555555555555555555555555555555555555555555555555555555555555555555(F

Euation (05 Pin Comine# Stress3 !on Mises55555555555555555555555555555555555555555555555555555555555555555555555555555(F

Euation (+5 Contact Stress @al- Wi#th IJ555555555555555555555555555555555555555555555555555555555555555555555555555555555(Euation (F5 Contact Stress Ma:imum Pressure I J55555555555555555555555555555555555555555555555555555555555555555555(

Euation (5 Wel# Loa# IDJ55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555(

Euation (5 Allowale Pin Tensile Strength3 I0J e .+'F1555555555555555555555555555555555555555555555555555555555555(+

Euation 05 E--ective Wi#th Criteria3 I0J e .+'F155555555555555555555555555555555555555555555555555555555555555555555555(+Euation +5 E--ective Wi#th3 I0J e .+'FD1555555555555555555555555555555555555555555555555555555555555555555555555555555555555(+

Euation F5 Allowale Single Plane "racture Strength3 I0J e .+'F)15555555555555555555555555555555555555555555(+

Euation 5 Allowale 4oule Plane Shear Strength3 I0J e .+'F15555555555555555555555555555555555555555555555(+

Euation 5 Total Area o- Shear Planes3 I0J e .+'* ? C+'01555555555555555555555555555555555555555555555555555555(+Euation D5 Allowale Bearing Stress3 I0J e .+'(155555555555555555555555555555555555555555555555555555555555555555555(+

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29ective

The o7ective o- this analysis was to vali#ate the #esign a#euacy o- the station + li-t

-i:ture, li-ting clevis an# link 2in5 This vali#ation consiste# o- #etermining -actors o- sa-ety -or

the res2ective com2onents when 2roo- teste#5 "urthermore, the stress #istriutions -or the li-ting

clevis an# link 2in were investigate# at loa# rating levels o- an a#7acent rigging com2onentan

actuator5 The aim was to #etermine whether the clevis an# 2in loa# rating coul# e matche# to

the actuator5

)acgroun(

Proo- testing is reuire# -or all in house -aricate# li-ting com2onents which inclu#e thestation + hoistli-t -i:ture, li-ting clevis an# link 2in5 Sa-ety stan#ar#s reuire 2roo- testing at

(0G o- the ma:imum antici2ate# in service loa#5 Previous estimate# weight -or the hal- 2erio#

.@P1 an# hoistli-t -i:ture structure is 0F ki2s I(J5 "urthermore, simulation o- station + -iel#

2erio# assemly ."PA1 reveale# ma:imum in service loa#s o- () ki2s, (*5*) ki2s, an# (+5)

ki2s, -or hoistli-t -i:ture li-t 2oints (, 0, an# + res2ectively, re-er to -igure ( I(J5 There-ore, the

reuire# 2roo- test loa#s -or the li-t -i:ture are 005 ki2s, (05 ki2s an# (D5( ki2s, -or li-t 2oints (,

0, an# + res2ectively5

The li-ting clevis an# link 2in reuire a minimum 2roo- testing o- at 0)50 ki2s .(0G o-

005 ki2s .(0G o- () ki2s1, the ma:imum antici2ate# in'service loa#ing515 @owever, these

com2onents are use# in con7unction with an actuator rate# -rom the manu-acturer at * ki2s5 "or

a##itional sa-ety, PPPL has limite# rate# the actuator to a ma:imum loa# o- at +0 ki2s5 Since

versatility is gaine# when the li-t com2onents match in loa# rating, it is #esirale to use the clevis

an# 2in at the actuator rate# value5 There-ore, stress levels were investigate# -or 2roo- testing at

F* ki2s .(0G o- +0 ki2s155

(


12/35

'eto(s

The material 2ro2erties use# -or this analysis are liste# in tale (5 "or this analysis it was

assume# that the material 2ro2erties an# characteristics are homogenous an# uni-orm throughout

the volumes o- the com2onents5 Com2ute# Ai#e# 4esign .CA41 mo#els were create# using

ProEngineer so-tware5 "inite element mo#els ."EM1 were create# an# -inite element analyses

."EA1 were 2er-orme# using ProMechanica .ProM1 an# Ansys Workench .AWB1 so-tware5

"urthermore, analytical analysis was 2er-orme# in E:cel ase# on classical strength o- materials

euations5 e-er to the re-erences section -or the resource list an# to the a22en#i: -or the

euations use#5

%ote3 ASME BT@'('0** Design of Below the Hook Lifting Devices I0J 2rovi#es the -ollowingcomments -or evaluation o- "EA results use# in con7unction with BT@'('0**5

BTH-1-2005 is based on classical strength of aterial ethods! These

ethods effectivel" co#$te average stresses acting on str$ct$ral % echanicaleleents! The effects of stress concentrations are not norall" re&$ired for static

strength of a lifter' b$t are ost i#ortant when deterining fatig$e life!

Peak stresses d$e to discontin$ities do not affect the $ltiate strength of a

str$ct$ral eleent $nless the aterial is brittle! The t"#es of steel on which this(tandard is based are all d$ctile aterials! Th$s' static strength a" reasonabl"

be co#$ted based on average stresses! Linear )*+ will t"#icall" show #eak stresses that indicate fail$re! This is #artic$larl" tr$e when eval$ating static strength! ,hile the $se of s$ch ethods is

not #rohibited' odeling of the device and inter#retation of the res$lts deands

s$itable e#ertise to ass$re the re&$ireents of this standard are et witho$tcreating $nnecessaril" conservative liits for static strength and fatig$e life!

There-ore, the %CS& structural stan#ar#s I+J were use# as a asis -or evaluating "EA results5

"or A+ structural steel with yiel# strength + ksi3

Design Tresca Stress Value (Sm ):

( e&$als the lesser of . /2%ield (trength 3 24 ksi

/1%2ltiate (trength 3 26 ksi!

(tress +llowable Priar" (tress 7 Bending (tress Condition. 8 1!5( 3 9 ksi!

(tress +llowable Total Priar" (tress 7 (econding (tress Condition. 8 ( 3 :2 ksi!

+llowable Bearing (tress 8 ield (trength 3 9 ksi!

0


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"or @S steel with yiel# strength (+* ksi3

Design Tresca Stress Value (Sm ):

( e&$als the lesser of . /2%ield (trength 3 ;: ksi

/1%2ltiate (trength 3 :5 ksi!

(tress +llowable Priar" (tress 7 Bending (tress Condition. 8 1!5( 3 11 ksi!

(tress +llowable Total Priar" (tress 7 (econding (tress Condition. 8 ( 3 225 ksi!

+llowable Bearing (tress 8 ield (trength 3 10 ksi!

Figure #/ Station 3* Lift !oint Layout in 'axi.u. Loa( Configuration B#/

5a9le #/ 'aterial !roperties/

Structural Steel A36

Elastic Modulus: E = 29.0 E3 ksi

Tension Yield Strength: Sty = 36 ksi

Tension Ultiate Strength: Stu = !" ksi

+


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Lift Link Pin: SAE J429 Grade 8

Elastic Modulus: 29.0 E3 ksi

Tension Yield Strength: #30 ksi

Tension Ultiate Strength: #!0 ksi

Hoist Lift Fixture Structural Analysis

A -inite element mo#el ."EM1 o- the hoistli-t -i:ture was create# an# a linear -inite

element analysis ."EA1 2er-orme# using oth ProMechanica an# AWB nsys Workench

so-tware 2lat-orms5 A ProMechanism simulation o- the station + -iel# 2erio# assemly ."PA1

-acilitate# vector estimates o- the ma:imum in service loa#s I(, F, J5 "EA was 2er-orme# at the

loa#s o- 005 ki2s, (05 ki2s an# (D5( ki2s with corres2on#ing unit vectors -or li-t 2oints (, 0,an# + res2ectively5 e-er to tale (0 -or li-t 2oint 2roo- loa#s an# unit vectors5 an# tale 0 -or the

material 2ro2erties use# in the analysis5 "igures 0 an# + #e2ict the "EA results otaine# -rom

ProMechanica, -or li-t 2oint ( -igures F an# re2resent the results -rom AWBnsys Workench5

The ProMechanica results show a 2eak !on Mises stress o- 005) ksi The AWB Workench

results show a 2eak !on Mises stress o- (5 ksi5 %ote, oth initial "EM


15/35

) *atio +l,%-

# 0.! 22!00/

0.#!3" 0.9"36 0.0#"!06 $!6

2 0.2 #2600/

0.2#2# 0.96269 0.0"9" %!4

3 0.! ##00

/

0.00966 0.99303 0.##3 %!8

Lift Points: Proof Loads & Unit ectors!

$i%t &oint ) $oad *atio Magnitude +l,%- e' ey e(

# 0.! 22!00 /0.#!3" 0.9"36 0.0#"!06

2 0.2 #2600 /0.2#2# 0.96269 0.0"9"

3 0.! ##00 /0.00966 0.99303 0.##3

5a9le 3/ 'aterial !roperties/

Structural Steel A36

S1eci%ic eight: = 0.2" l,%4in3

Elastic Modulus: E = 29.0 E3 ksi*igid Modulus: 5 = ##.0 E3 ksi

Tension Yield Strength: Sty = 36 ksi

o1ression Yield Strength: Scy = 36 ksi

Tension Ultiate Strength: Stu = !" ksi

o1ression Ultiate Strength: Scu = !" ksi

Figure / Lift !oint #* !ro'ecanica F0'/


16/35

Figure 3/ Lift !oint #* !ro'ecanica F0A Results/

Figure ;/ Lift !oint #* Ansys Eor9enc F0'/


17/35

Figure =/ Lift !oint #* Ansys Eor9enc F0A Results/

Figure >/ Lift !oint * Ansys Eor9enc F0' & Analysis Results/

D


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Figure @/ Lift !oint 3* Ansys Eor9enc F0' & Analysis Results/

)


19/35

Lift Clevis an( Lin !in Analysis

Analytical calculations an# non'linear "EA were 2er-orme# -or the li-t clevis an# link

2in, -irst ase# on the actuator loa# rating an# then ase# on the ma:imum e:2ecte# in'service

loa#ing5 to #etermine 2roo- test stress levels an# estalish allowale loa#s5 e-er to the a22en#i:

-or the euations use#5 e-er to -"igure ) #e2icts the CA4 -or a mo#el o- the clevis an# 2in5 an#

tales 0 an# + list -or the material 2ro2erties use# in thise analysis5 %ote, -igure ) contains a

2ortion o- the actuator an# also a a shackle 2in5 Both o- theseThis is a are commercial items an#

are loa# loa# rate# 2er the manu-acturer5 There-ore, it was these 2arts were not analy;e#, ut was

ere inclu#e# -or visual re-erence only5 "igure 2rovi#es the clevis geometry an# -igure (* the

link 2in5 There are F"our -ailure mo#es are 2ossile -or the clevis3 tension, s2litting, shear, an#

#ishing, re-er to -igure (( I)J5 an# There are two 0 -ailure mo#es -or the link 2in3 shear an# en#ing5 re-er to -igure (( I)J5 Per ASME I0J, analysis -or the #ishing -ailure mo#e,, -igure ((#,

is accounte# -or in the stan#ar#5 can e ignore#5 Tale F+ lists the allowale loa#s calculate# -or

the clevis #etermine# via ase# the ASME I0J gui#elines5 , re-erence the a22en#i: -or the

euations5Tale F 2rovi#es a summary o- the analytical results, .sa-ety -actors ase# on yiel#1

an# -igures (0 an# (+ #e2ict the results o- the "EA5 loa# analysis5 %ote, three loa#ing levels

were evaluate#5 The -irst was F* ki2s, an# was use# to evaluate i- the clevis an# 2in coul# e

loa#e# at the actuator ma:imum rating o- +0 ki2s5 The analysis reveale# this was not 2ossile5

Conseuently, a##itional analyses were 2er-orme# in or#er to #etermine the ma:imum 2roo- test

loa#5 This is + ki2s5 The thir# loa# level re-lects the ma:imum antici2ate# in service loa# an# is

inclu#e# to 2rovi#e insight into the in service stress levels5

5a9le ;/ 'aterial !roperties/

Lift Link Pin: SAE J429 Grade 8

Elastic Modulus: 29.0 E3 ksi

Tension Yield Strength: #30 ksi

Tension Ultiate Strength: #!0 ksi

&oisson7s *atio 0.32


20/35

Figure $/ Clevis & Lin !in 'o(el/

Shackle Pin

Link PinClevis

Actuator

Shackle Pin

Link PinClevis

Actuator

(*


21/35

Figure / Station 3 Lift Clevis 1eo.etry/

Figure #%/ Station 3 Lin !in 1eo.etry/

((


22/35

Figure ##/ Lug & !in Connection Failure 'o(es B$/

5a9le =/ Clevis Allo-a9les/5a9le >/ Clevis Allo-a9le Lao(s/

le'is Section $a()

&t# ##"320 l,% 8lloa,le Tensile Strength through &in ole

&,# "!#!3 l,% 8lloa,le Single &lane ;racture Strength ,eyond &in ole

8


23/35

(+


24/35

5a9le @/ Analysis Results Su..ary/5a9le $/ Analytical Results Su..ary/

o,-onent Stress ."-e A---lied Loadin/ Safet" #actor at

40 ki-s 22!% ki-s $8 ki-s 22!% ki-s $8 ki-s

le


25/35

Results Discussion

Lifting Clevis

6-ten, li-ting com2onents are -orge# or cast 2arts5 Suseuently, a higher con-i#ence is

retaine# when material 2ro2erty assum2tions are a22lie# to these 2arts, i5e5 homogenous, uni-orm

etc5 8n contrast, material 2ro2erties in wel# heat a--ecte# ;ones can not e assume# with high

con-i#ence5 The li-ting clevis, ma#e -rom A+ structural steel, is a wel#e# item as s2eci-ie# y

#rawing se()'+(D5 Conseuently, the 2revious material 2ro2erty assum2tions -or the clevis are

limite#55

The #esire was to ma:imi;e the use-ulness o- the li-ting clevis an# link 2in y 2roo-testing them at F* ki2s, .(0G o- the actuator


26/35

ki2s5 These values are well aove the #esire# 2roo- loa# an# antici2ate# in service loa#s,

2rovi#ing a sa-ety -actor o- F5*D -or 2roo- loa#ing an# 5 -or in service loa#ing5 The earing

stress gui#elines use# were not inten#e# as a strength limit, ut Nserve to control #e-ormation an#

wear o- the 2late I0J5O The earing stress limit is 00** ksi5 Ma:imum clevis earing stress, re-er

to tale , is (*5 ksi locate# in clevis section S05 This 2rovi#es a earing stress sa-ety -actor o-

05*5

Link Pin

(


27/35

Figure #/ Non"Linear F0A Results G ;% ips/

Figure #3/ Non"Linear F0A Results G /= ips/

(D


28/35

()


29/35

#/ Discussion

05

+5F5 Mention concerns aout wel# e--ects on clevis5

5

5 ecommen# 46 %6T WEL4 the nut to the link 2in5D5

)5

5(*5

((5

(05

(+5(F5

(5

(5(D5

()5

(50*5

0(5

005

0+50F5

05

050D5

0)5

05+*5

(


30/35

+(5

3/

Su..ary

Structural analyses 2rovi#e# estimates -or the stresses antici2ate# #uring hoist 2roo-

testing o- the station + li-t -i:turestructure, li-ting an# clevis5 an# link 2in5 The li-t -i:ture was

analy;e# -or three 2roo- test con-igurations5 The -irst con-iguration, which accounts -or the

ma:imum in service loa#, is -rom li-t 2oint (, an# reuires a 2roo- loa# o- 005 ki2s5 Proo- loa#s

o- (05 ki2s an# (D5( ki2s are reuire# -or li-t 2oints 0 an# + res2ectively5 "inite element

analyses show 2eak !on Mises stresses o- .(5'005)1, 5+, 5() ksi -or li-t 2oints (, 0, an# +

with corres2on#ing sa-ety -actors o- (5, 5F, an# 5) res2ectively5 The hoistli-t -i:ture was

analy;e# -or three 2roo- test con-igurations5 The -irst con-iguration -rom li-t 2oint (, which

accounts -or the ma:imum in service loa#, reuire# a 2roo- loa# o- 005 ki2s an# resulte# in a

2eak stress o- (5'005) ksi5 Con-iguration 0, li-t 2oint 0, reuire# a 2roo- loa# o- (05 ki2s an#

resulte# in a 2eak stress o- 5+ ksi5 Con-iguration +, -rom li-t 2oint +, reuire# (D5( ki2s an#

resulte# in a 2eak stress o- 5() ksi5 The li-ting clevis is 2roo- teste# at F* ki2s5 Analytical stress

com2utations reveale# ma:imums o- (5D, F5+, (*50 ksi -or tensile, shear, an# earing stresses

res2ectively5 The wel# loa# is (F0 l->in, an# using the #esigne# -illet wel# o- H inch 2rovi#es a

wel# sa-ety -actor +55

The #esire was to ma:imi;e the use-ulness o- the li-ting clevis an# link 2in, y 2roo-

testing them at (0G o- the actuatorin5 =sing a H -illet wel# as

s2eci-ie# on the #rawing 2rovi#es a sa-ety -actor o- 55

0*


31/35

References

(5 Brown, T5 Analysis 2er-orme# on the "PA station + li-t -i:ture -or its "4

%CS&'CALC'()'**0'**5 (* 4ec5 0**D5

05 ASME5 BT@'('00* 4esign o- Below the @ook Li-ting 4evices5 0**5+5 Qat;, 85 R5, %CS& Structural 4esign Criteria %CS&'C8T'C96'**5 0**F5

F5 Brown, T5 E:cel "ile3 trace**_2athtom+r(+right5:ls5

5 ProMechanism Simulation "iles3 st'-2a_mech_le-tsi#e5asm, st'-2a_mech_rightsi#e5asm55 Shigley5 Machine 4esign Dth e#5 0**F5

D5 Blo#gett, 6, W5 4esign o- Wel#e# Structures5 (5

)5 4uerr, 45 Pinne# Connection Strength an# Behavior5 0**5 Rournal o- Structural Engineering5"e5 2 ()0'(F5

0(


32/35

Appen(ix

e-er to -igure (F+F -or a22lying euations ('D5

0?uation #/ Allo-a9le !in 5ensile Strengt* B e? 3";=:/

eff

d

$t tb


33/35

d

"


34/35

Figure #@/ !in Sear & )en(ing 'o(el/

Figure #$/ !in Sear & )en(ing 'o(el/

0?uation $/ !in 'o.ent interval Ba 9/

( ) ( )((

(0

-T

- > +

−=

0?uation / !in Sear interval B9 c/

( )

+

−=

0B500 00

T -

T -?

0?uation #%/ !in 'o.ent interval B9 c*

( ) ( )

++

−=

0B500(0B5(

0

0

0

00

T - -

T - >

0?uation ##/ !in Nor.al Stress fro. )en(ing/

-

- - @

>c f

==σ

0?uation #/ !in Co.9ine( Stress* on 'ises B/

000

+ v " " - -cr f f f f f f ++−=

e-er to -igure (F -or a22lying euations (+ an# (F an# -igure (D -or euation (5

Figure #/ Contact Stress 'o(el/

Figure %/ Contact Stress 'o(el/

L

F

F

9

(#

(

000+

v " " - -cr f f f f f f ++−=

0F


35/35

0?uation #3/ Contact Stress Half Ei(t B>/

( ) ( )

0(

0

0

0

(

0

(

((

((

0

d d

* *

l

) b

+

−+

−

=

υ υ

π

0?uation #;/ Contact Stress 'axi.u. !ressure B> /

bl

) #

π

0

ma: =

Figure #/ Eel( Loa( 'o(el/

Figure / Eel( Loa( 'o(el/

0?uation #=/ Eel( Loa( B@/

d b

T

+rea

)orce Load

weld

weld 00

0

+

==

Documents

Analysis Report Station 3 Lifting r4