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A BACKHOE LOADER
A PROJECT REPORT
Submitted by
Alperen KALE
Cantrk SANAN
Fetihhan GRAN
M.Emre PAKSOY
HACETTEPE UNIVERSITY
MAY 2015
ABSTRACT
This is the final and third report of the stationary backhoe design project. This project is
combination of both design of systems and selection of systems. Design of systems includes
all the necessary calculations of a mechanical system, such as; static, dynamic, stress, fatigue
analysis so on and so forth. All of the calculations carried out with the help of Statics,
Dynamics, Strength of Materials, Design of Machine Elements and in particular Vehicle
Component Design courses. Selection of systems depends on online part selection tools of
firms and inspection of equivalent systems. These two main design processes combined
together to constitute the proper stationary backhoe for required work conditions with the
comprehensive effort of group members.
Table of Contents
I.
Introduction ......................................................................................................................... 3
A. Problem Statement .......................................................................................................... 3
B. Motivation ....................................................................................................................... 3
C. Challenges and Goals ...................................................................................................... 3
D. Work Plan ........................................................................................................................ 4
ii
List of Tables
Table 1 - Task timetable ............................................................................................................. 4
Table 2 - Pugh Chart .................................................................................................................. 6
Table 3 - Cost Table ................................................................................................................. 55
List of Figures
Figure 1 - Free body diagram of the Bucket .............................................................................. 7
Figure 2 - Free body diagram of the Stick ................................................................................. 7
Figure 3 - Free body diagram of the Boom ................................................................................ 8
Figure 4 - Critical points of Factor of Safety ........................................................................... 53
Figure 5 - Critical points of Factor of Safety ........................................................................... 53
Figure 6 - Fatigue analysis and total life .................................................................................. 54
Figure 7 - Static Factor of Safety Critical points ..................................................................... 54
Figure 8 - Side view technical drawing of closed position ..................................................... 56
Figure 9 - Top view technical drawing of closed position ....................................................... 56
Figure 10 - Front and back view technical drawing ................................................................ 57
Figure 11 - Top view technical drawing of opened position.................................................... 58
Figure 12 - Isometric view technical drawing of opened position ........................................... 58
Figure 13 - Isometric view technical drawing of closed position ........................................... 59
Figure 14 - CAD view 1 ........................................................................................................... 60
Figure 15 - CAD view 2 ........................................................................................................... 60
Figure 16 - CAD view 3 ........................................................................................................... 61
iii
I.
Introduction
A. Problem Statement
Stationary backhoes are widely used in almost every mass production sector to carry
products from one place to another effectively. One can examine and find out that these
backhoes are mostly over safe and oversize for most applications. This projects aim is to
design a stationary backhoe which is safe enough, less cost and capable of performing the
duty without any restrictions.
B. Motivation
The basic reason behind this project is to prevent large amount of energy losses which are
produced while the production of these oversize backhoes and during the operation of these
backhoes. Realizing that the most urgent problems of the World are the energy shortage and
the climate change which is directly affected by the energy production methods, even a small
amount of energy gain is very important.
D. Work Plan
1. Preparing first report and completing literature survey: 1st and 2nd weeks.
2. Completing hand calculations: 3rd and 4th week.
3. Machine components design (Shafts and Bearings): 5th week.
4. Schematic drawings: 6th week.
5. Setting Second Report: 7th week.
6. CAD drawings and FEM analysis: 8th week.
7. Machine components design: 9th week.
8. Technical drawings- Parts list cost analysis: 10th week.
9. Setting final report- Preparing presentation: 11th week.
II.
A. Literature Survey
At the beginning of this project the textbook has been exhaustively examined. A general
idea about for each component has gained by group members. Afterwards applications of
these component has been researched and compared with similar ones. These researches are
made via internet or speaking with the firms at phone.
Some of these sources;
1. How Caterpillar Backhoe Loaders Work
http://science.howstuffworks.com/transport/engines-equipment/backhoe-loader1.htm
2. New Backhoe Loaders CAT 422F
http://www.cat.com/en_ZA/products/new/equipment/backhoeloaders/sideshift/18346265.html
3. CAT Backhoe Loader Brochure
http://s7d2.scene7.com/is/content/Caterpillar/C768535
4. Backhoe Loader
http://en.wikipedia.org/wiki/Backhoe_loader
5. Backhoe
http://opensourceecology.org/wiki/Backhoe
6. SKF Rolling Bearings
http://www.skf.com/binary/138-121486/SKF-rolling-bearings-catalogue.pdf
7. SKF Extra Power Belts
http://www.skf.com/binary/92-118145/Xtra-Power-belts---10552_3-EN.pdf
8. SKF Belt Drive Design Calculations Tool
http://www.skf.com/group/knowledge-centre/engineering-tools/belt-drive-designcalcalutions-tool.html
9. Gamak 3 Phase Asynchronous Electric Motors
http://www.gamak.com/images/urun-pdf/standart_motorlar.pdf
B. Pugh Chart
Reference Design 1
Reference Design 2
Our Design
0
0
0
0
Table 2 - Pugh Chart
C. Design Approach
The basic design approach of this project rely on the motivation of this project. The
sufficient and necessary design method for less energy loss is downsizing. Cost of the project
is another issue that has to be minimized, avoiding from over safe parts will result less energy
loss and less cost. The reliability of this stationary backhoe must be satisfactory so an
optimization is essential between downsizing approach and safety. Such an optimization has
been considered through whole project.
D. Schematic Drawing
III.
In this part static analysis, dynamic analysis have been made by hand calculations. Also
stress and fatigue analysis have been completed by hand calculations. Assumptions needed to
make analysis are decided after an intense literature survey. A rough sketch of boom, stick
and bucket is completed.
Decision and design of back parts of the system such as electirc motor, shafts and
bearings are made according to necessary power to carry a 500 kg load. The static analysis for
bucket is made in this part.
To begin with, the mass of bucket is assumed as 200 kg and a factor of safety is
considered as 4. The factor of safety is used at the begining of static analysis instead of using
at the end of the stress values consideration.
The desired maximum load is 500 kg. The calculations are made due to this approach,
and therefore the maximum load is taken as 2000 kg. According to this value, the piston
forces and the reactions forces are determined. The formulas and calculations are shown
below.
A. Stat c Analys s
1. Bucket:
Bucket mass
mbucket 200 kg
mload 500 kg
Bucket length
Lbucket 130 cm
bucket 70
b.closed 30
db.p 45 cm
Bucket jo nt d stance
db.j 20 cm
St ck to ground angle
s.g 0
Factor of Safety
FoSbucket 4
P ston 1 Force:
Lbucket
mload FoSbucket + mbucket g
cos b.closed
2
FP1
db.p sin bucket db.j
FP1 = 54.494 kN
10
2.St ck:
The mass of st ck, lengths and angles are assumed and g ven below. Due to these
values, the react ons and p ston forces are determ ned.
St ck Length
Lstick 2.6 m
St ck Mass
mstick 200 kg
ds.p1 25 cm
p2.g 30
St ck arm jo nt 2 to jo nt 3 d stance
ds.j2.j3 60 cm
P ston 2 Force:
Lstick
mstick g + R1y Lstick FP1 ds.p1
2
FP2
sin p2.g ds.j2.j3
FP2 = 150.067 kN
11
3.Boom:
The mass of boom, shape, lengths and angles are assumed and g ven below. Due to
these values, the react ons and p ston forces are determ ned.
Boom length 1
Lb1 1.5 m
Boom length 2
Lb2 1.7 m
Mass of boom
mboom 350 kg
p3.g 60
CoG of Boom to jo nt 3
perpend cular d stance
dcogb.j3 = 0.85 m
dp3.j3 ds.j2.j3 sin p2.g
P ston 3 to jo nt 3
perpend cular d stance
dp3.j3 = 0.3 m
12
13
B. Stress Analys s
1.Bucket:
Wbucket 70 cm
W dth of bucket
Abucket = 1.365 m
mload FoSbucket
bucket
g
Abucket
S nce the total stress s too small the stress analys s s not necessary. The bucket
w ll not fa l.
2. St ck:
The lengths (w dth, he ght and wall th ckness) of st ck and ts prof le are assumed and
g ven below. Due to these values, the stress analys s s done and the results are shown.
W dth of st ck
wstick 200 mm
He ght of st ck
hstick 150 mm
Wall th ckness of st ck
sstick 10 mm
Jo nt d ameter
Djoint 50 mm
Kt.stick 2
Area of st ck:
Astick hstick wstick hstick 2 sstick wstick 2 sstick 2 Djoint sstick
Astick = 0.006 m
14
Ax al Stresses:
FP1 + R1x R2x
a.stick
Astick
Bend ng Stresses:
Lstick hstick
hstick
hstick
mstick g
R1y Lstick FP1 ds.p1
2
2
2
2
b.stick +
Istick
Istick
Istick
b.stick = 144.946 MPa
Total Stresses:
tot.stick a.stick + b.stick Kt.stick
tot.stick = 243.477 MPa
3. Boom:
The lengths (w dth, he ght and wall th ckness) of st ck and ts prof le are assumed and
g ven below. Due to these values, the stress analys s s done and the results are shown.
W dth of Boom
wboom 350 mm
He ght of Boom
hboom 300 mm
sboom 30 mm
Kt.boom 1.5
Area of Boom
Aboom hboom wboom hboom 2 sboom wboom 2 sboom
Aboom = 0.035 m
15
Ax al Stresses:
FP2 + R2x FP3 cos p3.g
a.boom
Aboom
cos p3.g
Bend ng Stresses:
hboom FP3 dp3.j3 FP2 dp2.j3 mboom g dcogb.j3 R2y dj2.j3x
b.boom Kt.boom
+
+
+
2
Iboom
Iboom
Iboom
Iboom
bpj 42 MPa
Pbpj 40 MPa
D ameter of bucket p n jo nt
dbpj 50 mm
Length of bucket p n jo nt
Lbpj 300 mm
16
Lbpje 225 mm
Effect ve length of p n jo nt
dbpj
Ymax.bpj
2
Ymax.bpj = 25 mm
2
2
R1y + R1x
R1xy
R1xy = 58.61 kN
R1xy
Pbpj1
dbpj Lbpje
Abpj 2 dbpj
4
Area of p n bucket jo nt
2
3
Abpj = 3.93 10 m
R1xy
bpj1
Abpj
Wbpj Lbpje
Mbpj
8
Ibpj dbpj
64
N
Wbpj = 260.488
mm
6
Mbpj = 1.648 10 N mm
5
4
Ibpj = 3.068 10 mm
17
Mbpj Ymax.bpj
bpj
Ibpj
spj 42 MPa
Pspj 40 MPa
D ameter of bucket p n jo nt
dspj 75 mm
Length of bucket p n jo nt
Lspj 380 mm
Effect ve length of p n jo nt
Lspje 275 mm
dspj
Ymax.spj
2
Ymax.spj = 37.5 mm
2
2
R2xy
R2y + R2x
R2xy = 163.114 kN
R2xy
Pspj1
dspj Lspje
Aspj 2 dspj
4
3
2
Aspj = 8.84 10 m
18
R2xy
spj1
Aspj
Wspj Lspje
Mspj
8
Ispj dspj
64
6
Mspj = 5.607 10 N mm
4
6
Ispj = 1.553 10 mm
Mspj Ymax.spj
spj
Ispj
N
Wspj = 593.141
mm
Boom jo nt
Mater al IS2062
Stress l m t for bucket p n
jo nt
bopj 42 MPa
Pbopj 40 MPa
D ameter of bucket p n jo nt
dbopj 120 mm
Length of bucket p n jo nt
Lbopj 380 mm
Effect ve length of p n jo nt
285
19
Lbopje 285 mm
Effect ve length of p n jo nt
dbopj
Ymax.bopj
2
Ymax.bopj = 60 mm
2
2
R3xy
R3y + R3x
R3xy = 663.144 kN
R3xy
Pbopj1
dbopj Lbopje
Abopj 2 dbopj
4
Area of p n bucket jo nt
3
2
Abpj = 3.93 10 m
R3xy
bopj1
Abopj
R3xy
Wbopj
Lbopje
3
N
Wbopj = 2.327 10
mm
Wbopj Lbopje
7
Mbopj
Mbopj = 2.362 10 N mm
8
Ibopj dbopj
64
Mbopj Ymax.bopj
7
4
Ibopj = 1.018 10 mm
139.258 MPa
20
Mbopj Ymax.bopj
bopj
Ibopj
C. Dynam c Analys s
St ck Analys s
21
Accord ng to th s angular veloc ty, dynam c force analys s has been evaluated:
2
Boom Analys s
Same approach wh c has been used for st ck dynam c analys s s also used for
boom analys s.
mboom
mcombined.b mstick + mbucket + 4 mload +
2
mcombined.b = 2575 kg
22
The angular veloc ty g ven below s the angular veloc ty of the boom at z ax s.
rad
boom
4 s
Accord ng to th s angular veloc ty, dynam c force analys s has been evaluated:
2
Tens le strength
Endurance l m t
ka 0.88
kb 0.667
kd 1
ke 0.814
kf 1
23
Corrected endurance l m t:
Se = 189.418 MPa
Se ka kb kd ke kf S'e
1. St ck Analys s
Lstick hstick
hstick
hstick
mstick g Fsmax.y Lstick FP1 ds.p1
2
2
2
2
Kt.stick
b.stick.max +
Istick
Istick
Istick
Lstick hstick
hstick
hstick
mstick g Fsmin.y Lstick FP1 ds.p1
2
2
2
2
b.stick.min +
Kt.stick
Istick
Istick
Istick
24
2. Boom Analys s
cos p3.g
Kt.boom 0.41
hboom FP3 dp3.j3 FP2 dp2.j3 mboom g dcogb.j3 Fbmax.y dj2.j3x
+
+
+
b.boom.max Kt.boom
2
Iboom
Iboom
Iboom
Iboom
25
2
Iboom
Iboom
Iboom
Iboom
NOTE: All the factor of safet es are actually 4 t mes of the r values s nce at the
beg nn ng of the analys s load has taken to be 2000 kg nstead of 500 kg.
26
y
Vy
tlift
m
Vy = 1.25
s
y
mstick g
mload + mbucket g y
2
Py
+
tlift
tlift
Py = 9.807 kW
rbucket = 3.95 m
rstick = 4.103 m
27
rboom = 1.5 m
2
3
Istick.p = 3.367 10 kg m
2
4
Ibucket.p = 1.092 10 kg m
Iboom.p = 787.5 kg m
Act ng toqrue:
Iboom.p + Istick.p + Ibucket.p
= 5919.562 N m
28
Pdet
14.456 kW
29
When des gn ng the shaft, s m lar appl cat ons are researched. The
conven ent mater al for th s shaft s determ ned as AISI 440 C steel.
The propert es of shaft are g ven below:
Length of shaft
L2 m
Y eld strength
y 450 MPa
Shear modulus
G 77.2 GPa
Elas c modulus
E 210 GPa
Dens ty
kg
7800
3
m
y 0.5
Factor of safety
Allowable shear stress:
all
n
all = 93.75 MPa
16
T
all
d = 2.748 cm
30
Mass of shaft
d
mL
4
m = 11.027 kg
Wmg
We ght of shaft
W = 108.138 N
W
wdist
L
d
J
32
8
4
J = 7.952 10 m
I d
64
4
8
I = 3.976 10 m
Angular deflect on
T L 360
t
JG 2
t = 7.13
Bend ng deflect on
4
5 wdist L
max
384 E I
3
max = 1.349 10 m
max
The max mum speed s lower than requ red speed of shaft. So the new
d ameter s selected as 4 cm
31
d 4 cm
D ameter of shaft
Mass of shaft
d
mL
4
m = 19.604 kg
Wmg
We ght of shaft
W = 192.245 N
W
wdist
L
d
J
32
4
7
J = 2.513 10 m
I d
64
4
7
I = 1.257 10 m
Angular deflect on
T L 360
t
JG 2
t = 2.256
Bend ng deflect on
4
5 wdist L
max
384 E I
4
max = 7.588 10 m
max
Max mum speed s h gher than the requ red speed. So t can be used.
32
2. Bear ng Select on
L fe assumpt on:
It s assumed that the backhoe w ll work 30 years,
9 month per year and 8 hour per day
60
Life 750 30 270 8
6
10
Life = 2.916 10
ka 1.1
W
Fb
2
C
m ll on cycle
kr 1
a3
Life ka Fb
C = 1.511 kN
Bearing selection
Deep groove ball bearing is choosen because of low radial forces
C0
4,94
3,45
26000
16000
33
Reduct on rat o
Np
RR
Nem
RR = 7.333
Des gn Cr ter on
RRG 5
RRB = 1.467
Nmain Nem
3
Npinion = 3.75 10 rpm
P 30 kW
L 100 10
50 HRC
m 4 mm Assumption
zpinion 20
dpinion m zpinion
dpinion = 80 mm
Npinion
dpinion
dmain
Nmain
dmain = 400 mm
34
b 10 m
b = 40 mm
J 0.35
m
V = 15.708
s
P
Tpinion
Npinion
Tpinion = 76.394 N m
Ft = 0.955 kN
From graph
1
Kv From graph
0.6
Km 1.3
Ko 1.25
From Table
Ft
pinion
Kv Ko Km
bmJ
kL 1
ut 240 MPa
kV 1
ks 0.8
'e 97 MPa
kr 0.814 (%99)
kt 1
kf 1
km 1.33
e 'e kL kV ks kr kt kf km
e = 84.011 MPa
m
V = 15.708
s
P
Tmain
Nmain
Tmain = 381.972 N m
Ft = 0.955 kN
35
J 0.35
From graph
1
Kv From graph
0.6
Km 1.3
Ko 1.25
From Table
Ft
Kv Ko Km
main
bmJ
ut 240 MPa
ut 1665 MPa
kL 1
kV 1
ks 0.8
kr 0.814 (%99)
kt 1
kf 1
km 1.33
e 'e kL kV ks kr kt kf km
e = 721.025 MPa
2
6
Cp 149 MPa
H Cp
KL 0.9
0.5
Ft
Kv Ko Km
b dpinion I
KT 1
sf 'sf KL KR KT
H = 339.983 MPa
KR 1
sf = 433.8 MPa
36
To calculate piston volumetric flow rate, piston rods speeds are needed. That
speed is directly depend on speed of bucket , stick and boom. That's why relation
between these speeds must be defined. These relation basically ratio of length piston
arms and parts length (bucket,stick,boom). On this assumption effect of angle
between parts are ignored to easier calculations.
Analysis have been made by pi/4 maximum lifting for boom and stick. But on a
combine movement these speeds will limited to pi/8 for each.
Movement on rotat&onal ax&s' &s not calculated because of these mot&ons w&ll
reduce each other on comb&ne movement to decrease forces that act&ng on arms and
s&ze of pump.
Distance between stick and piston 1
dp1 25 cm
dp2 30 cm
dp3 30 cm
rad
wbucket
2
s
rad
wstick
4 s
rad
wboom
8 s
Typical pressure for pistons are 300 bar but piston type pumps can reach
420 bar so 400 bar is selected and forces on pistons are already known
from report 2 than;
Hydraulic pressure for pistons
P 400 bar
Fp.1 54.494 kN
Fp.2 150.067 kN
Fp.3 639.652 kN
37
Area of piston 1
2
3
Ap.1 = 1.362 10 mm
Dp.1
1
4 Ap.1
Dp.1 = 41.649 mm
Dp.1 45 mm
to standardization
Dp.1
Ap.1
4
Fp.2
Ap.2
P
Area of piston 2
2
3
Ap.2 = 3.752 10 mm
Dp.2
1
4 Ap.2
Dp.2 = 69.114 mm
Dp.2 70 mm
2
Dp.2
Ap.2
4
Fp.3
Ap.3
P
Area of piston 3
Ap.3 = 159.913 cm
Dp.3
1
4 Ap.3
Dp.3 = 142.691 mm
Dp.3 145 mm
2
Dp.3
Ap.3
4
38
39
F. Simulation Results
40
Treated As
Solid Body
Volumetric Properties
Document Path/Date
Modified
Mass:115.931 kg
Volume:0.0147683 m^3
Density:7850 kg/m^3
Weight:1136.12 N
D:\Gen.V2\hyd.cyl\1.SL
DPRT
May 20 01:00:14 2015
Mass:71.1489 kg
Volume:0.00906355 m^3
Density:7850 kg/m^3
Weight:697.259 N
D:\Gen.V2\hyd.cyl\1.SL
DPRT
May 20 01:00:14 2015
Fillet3
Solid Body
41
Fillet3
Solid Body
Mass:28.0339 kg
Volume:0.0035712 m^3
Density:7850 kg/m^3
Weight:274.733 N
D:\Gen.V2\hyd.cyl\1.SL
DPRT
May 20 01:00:14 2015
Mass:13.5738 kg
Volume:0.00172914 m^3
Density:7850 kg/m^3
Weight:133.023 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:2.01023 kg
Volume:0.00025608 m^3
Density:7850 kg/m^3
Weight:19.7002 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:7.78129 kg
Volume:0.000991247 m^3
Density:7850 kg/m^3
Weight:76.2566 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:1.27543 kg
Volume:0.000162475 m^3
Density:7850 kg/m^3
Weight:12.4992 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:5.92278 kg
Volume:0.000754494 m^3
Density:7850 kg/m^3
Weight:58.0432 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Fillet1
Solid Body
Fillet1
Solid Body
Fillet1
Solid Body
Fillet1
Solid Body
Fillet1
Solid Body
42
Fillet1
Solid Body
Mass:2.01527 kg
Volume:0.000256723 m^3
Density:7850 kg/m^3
Weight:19.7497 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:5.92278 kg
Volume:0.000754494 m^3
Density:7850 kg/m^3
Weight:58.0432 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:2.27422 kg
Volume:0.000289709 m^3
Density:7850 kg/m^3
Weight:22.2873 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:5.36096 kg
Volume:0.000682924 m^3
Density:7850 kg/m^3
Weight:52.5374 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:2.49617 kg
Volume:0.000317984 m^3
Density:7850 kg/m^3
Weight:24.4625 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:6.29235 kg
Volume:0.000801573 m^3
Density:7850 kg/m^3
Weight:61.665 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Fillet1
Solid Body
Fillet1
Solid Body
Fillet1
Solid Body
Fillet1
Solid Body
Fillet1
Solid Body
43
Fillet1
Solid Body
Mass:7.78129 kg
Volume:0.000991247 m^3
Density:7850 kg/m^3
Weight:76.2566 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:253.134 kg
Volume:0.0322463 m^3
Density:7850 kg/m^3
Weight:2480.71 N
D:\Gen.V2\boom
rev1_V2.sldprt
May 20 00:39:00 2015
Mass:479.509 kg
Volume:0.0610839 m^3
Density:7850 kg/m^3
Weight:4699.18 N
D:\Gen.V2\boom_V2.SL
DPRT
May 19 17:27:25 2015
Mass:38.6272 kg
Volume:0.00492066 m^3
Density:7850 kg/m^3
Weight:378.546 N
D:\Gen.V2\bucketlink1_
V2.SLDPRT
May 20 00:36:35 2015
Mass:12.1638 kg
Volume:0.00154952 m^3
Density:7850 kg/m^3
Weight:119.205 N
D:\Gen.V2\bucketlink2_
V2.SLDPRT
May 20 00:36:07 2015
Mass:74.7706 kg
Volume:0.00952495 m^3
Density:7849.98 kg/m^3
Weight:732.752 N
D:\Gen.V2\bucketlink3_
V2.SLDPRT
May 20 00:35:41 2015
Fillet27
Solid Body
Fillet25
Solid Body
Fillet5
Solid Body
Fillet1
Solid Body
Fillet4
Solid Body
44
Fillet7
Solid Body
Fillet2
Cut-Revolve2
Fillet2
Cut-Revolve2
Fillet2
Cut-Revolve2
Solid Body
Solid Body
Solid Body
Solid Body
Solid Body
Solid Body
Mass:241.524 kg
Volume:0.0307674 m^3
Density:7850 kg/m^3
Weight:2366.93 N
D:\Gen.V2\myownbucket
2_V2.SLDPRT
May 19 15:47:21 2015
Mass:1.21139 kg
Volume:0.000154317 m^3
Density:7850 kg/m^3
Weight:11.8716 N
D:\Gen.V2\hyd.cyl\Holde
r.SLDPRT
May 20 00:16:58 2015
Mass:44.2107 kg
Volume:0.00563194 m^3
Density:7850 kg/m^3
Weight:433.265 N
D:\Gen.V2\hyd.cyl\Rod.S
LDPRT
May 20 00:24:40 2015
Mass:1.21139 kg
Volume:0.000154317 m^3
Density:7850 kg/m^3
Weight:11.8716 N
D:\Gen.V2\hyd.cyl\Holde
r.SLDPRT
May 20 00:16:58 2015
Mass:25.345 kg
Volume:0.00322866 m^3
Density:7850 kg/m^3
Weight:248.381 N
D:\Gen.V2\hyd.cyl\Rod.S
LDPRT
May 20 00:24:40 2015
Mass:1.21139 kg
Volume:0.000154317 m^3
Density:7850 kg/m^3
Weight:11.8716 N
D:\Gen.V2\hyd.cyl\Holde
r.SLDPRT
May 20 00:16:58 2015
Mass:7.32229 kg
Volume:0.000932776 m^3
Density:7850 kg/m^3
Weight:71.7584 N
D:\Gen.V2\hyd.cyl\Rod.S
LDPRT
May 20 00:24:40 2015
Mass:349.622 kg
Volume:0.0445379 m^3
Density:7850 kg/m^3
Weight:3426.3 N
D:\Gen.V2\stick
v2_V2.SLDPRT
May 20 00:24:39 2015
Fillet16
Solid Body
45
1. Study Properties
Study name
dinamik
Analysis type
Static
Mesh type
Solid Mesh
Thermal Effect:
On
Thermal option
298 Kelvin
Off
Inplane Effect:
Off
Soft Spring:
Off
Inertial Relief:
Off
Automatic
Large displacement
Off
On
Friction
Off
Off
Result folder
FFEPlus
Unit system:
SI (MKS)
Length/Displacement
mm
Temperature
Kelvin
Angular velocity
Rad/sec
Pressure/Stress
N/mm^2 (MPa)
46
Fixture Image
Fixture Details
Entities:
Type:
2 face(s)
Fixed Geometry
Fixed-1
Resultant Forces
Components
Reaction force(N)
Reaction Moment(N.m)
Load name
X
999.291
0
Y
27711.4
0
Load Image
Z
-999.718
0
Resultant
27747.4
0
Load Details
Entities:
Reference:
Type:
Values:
1 face(s)
Edge< 1 >
Apply force
---, ---, 10000 N
Reference:
Values:
Units:
st Dzlem
0 0 -9.81
SI
Entities:
Reference:
Type:
Values:
1 face(s)
Edge< 1 >
Apply force
---, ---, 1000 N
Force-1
Gravity-1
Force-2
47
Entities:
Reference:
Type:
Values:
1 face(s)
Edge< 1 >
Apply force
---, ---, 1000 N
Force-3
3. Mesh Information
Mesh type
Solid Mesh
Mesher Used:
Jacobian points
4 Points
209.247 mm
41.8494 mm
Mesh Quality
High
Off
387530
Total Elements
228594
235.1
66.6
3.45
% of distorted elements(Jacobian)
00:00:29
Computer name:
ALPEREN-PC
48
Control-1
Control-2
Control-3
Entities:
Units:
Size:
Ratio:
Entities:
Units:
Size:
Ratio:
49
Entities:
Units:
Size:
Ratio:
Control-4
3. Study Results
Name
Type
Min
Max
Stress1
3.17023e-005 N/mm^2
(MPa)
Node: 339287
Gen.V2-dinamik-Stress-Stress1
Name
Type
Min
Max
Displacement1
0 mm
Node: 62120
17.9871 mm
Node: 238767
50
Gen.V2-dinamik-Displacement-Displacement1
Name
Type
Min
Max
Strain1
1.62912e-010
Element: 6708
0.00169549
Element: 24045
Gen.V2-dinamik-Strain-Strain1
51
Name
Type
Min
Max
Factor of Safety1
Automatic
1.15534
Node: 45973
1.48254e+007
Node: 339287
52
53
This is the critical point of the first work. In order to avoid this huge stress concentration, the size
of joints are made bigger and stronger.
54
G. Cost Analysis
From-Brand
self
manufactur
Long Shaft ed
self
Short
manufactur
Shaft
ed
self
manufactur
Gearbox
ed
Belt-drive SKF
Stahl &
Clutch
Eisen
Electric
Motor
Gamak
Hydraulic
Pump
Parker
Bearings
SKF
Driven
Pulley
SKF
Driver
Pulley
SKF
self
manufactur
Boom
ed
self
manufactur
Stick
ed
self
manufactur
bucket
ed
self
manufactur
joints
ed
Casu
cylinders
hydraulic
Properties
Price of
Unit (TL)
Num
ber
Sum
(TL)
232.32
232.32
67.75
67.75
528
528
40.6
243.6
110
110
6705
6705
5108
158.6
1
4
5108
634.4
PHP 6SPZ90TB
90mm diameter
182.5
182.5
PHP 6SPZ132TB
132mm diameter
297.6
297.6
3980
3980
2850
2850
2000
2000
50-200
2000$*2.6
4
12
1440
5280
50-75-100-150mm diameters
45-70-145 mm diameters
Table 3 - Cost Table
55
H. 3D Drawings
56
57
58
59
60
61
IV.
B. Future Works
In our project the main approach was making the most optimal backhoe with high
speed and low cost. The cost depends on the material. In the future there will be more safer
materials with higher speed ability and lower cost. Also the manufacturing will cost less
because the technology will improve and that will cause decrease in cost. In other projects our
aim will be design a machine with longer life time, with safer material and high ability to
desired approach.
62
V.
REFERENCES
63
Engineering Skills
Firstly this project has improved the engineering skills of all of the group members.
All of the theoretical informations were used in order to get something perceptible. The most
important processes were the problems. Sometimes there was huge problems and it was hard
to solve them. Beacuse of these problems the project did not go easily straight forward. But at
this point all of the group members tried to create a way out and the brain stormings, which
are made during these problems were very important. During this continuum a lot of shiny
idea are took shape and the problems were solved. Besides the problems the technical drawing
and alaysis skills were improved.
This project was a good first step and a great experience for our engineering career.
Its sure that all of us will use these experiences and informations in the future.
64
APPENDICES
A. Sample Cost Analysis
Shaft Manufacturing Analysis
Model ad:
Long Shaft
5/20/2015 10:50:37 AM
Malzeme:
retim sreci:
Makineleme
55.03 lb
Stok tipi:
Block
Block Size:
1.57x1.57x78.74 in
Malzeme maliyeti/arl:
1.41 USD/lb
Shop Rate:
30.00 USD
retilecek Miktar
Toplam para says:
100
Lot bykl:
100
machiningtemplate_default(englishstandard).sldct
m
Karlatrma:
Maliyet Dalm
Malzeme:
77.59 USD
87%
retim:
11.27 USD
13%
Markup
0.00 USD
0%
00:05:35
lemler:
00:16:55
65
Maliyet Raporu
Model Ad:
Part1
Malzeme:
Plain Carbon
Steel
Malzeme maliyeti:
77.59 USD
retim maliyeti:
11.27 USD
Markup
Toplam maliyet
/para:
Toplam sre
/para:
88.85 USD
00:22:31
0.00 USD
Zaman (ss:dd:ss)
Maliyet (USD)
Setup Operation 1
00:00:36
0.30
Toplam
00:00:36
0.30
Zaman (ss:dd:ss)
Maliyet (USD)
Setup Operation 1
00:05:00
2.50
Toplam
00:05:00
2.50
Yzey
Cilas
karlan Hacim
(in^3)
Zaman
(ss:dd:ss)
Maliyet
(USD)
Volume 1
Roughing
10.48
00:04:13
2.12
Volume 2
Roughing
10.48
00:04:13
2.12
Volume 3
Roughing
10.48
00:04:13
2.12
Volume 4
Roughing
10.48
00:04:13
2.12
41.91
00:16:55
8.47
Freze lemi
Toplam
Aletle
ekillendir
me
Hacim
bana
Maliyet
(USD/in^3)
Flat End
Mill
Flat End
Mill
Flat End
Mill
Flat End
Mill
N/A
N/A
N/A
N/A
Kurulum lemleri
1. Setup Operation 1
a. Volume 4
b. Volume 2
c. Volume 3
d. Volume 1
2
66
B. Belt Specifications
67
68