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Rough Terrain Crain

FEA Report

Although Finite Element Analysis (FEA) has become a widely used tool for engineering analysis and design, it cannot be viewed as a complete
substitute for testing. If reasonable doubt is present after performing engineering hand calculations and developing FEA models, controlled testing
should be performed with reasonable loads and boundary conditions applied.

Project Title: Carrier & Upper Structure FEA


FEA Model Name: 300-0007_FEA.SLDASM
Prepared By:
Client Name:
Date: February 22, 2013

Specialty Systems Engineering 121 N. 1st Street Montevideo, MN 56265 (320) 269-3227
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Executive Summary
In an effort to prove the structural integrity of the CD4415, a Finite Element Analysis (FEA) was
conducted by Specialty Systems in 27 load scenarios of the carrier, 4 load scenarios of the upper
structure, and 1 load scenario as a result of real world manufacturing.

The CD4415 carrier is primarily made from Domex (for plate thicknesses less than 3/8in) and
T1 (for plate thickness greater than 3/8in) possessing yield strengths of 100,000psi (100ksi) and
110,000psi (110ksi) respectively.

Concerning the Carrier:


In some load scenarios considered, particularly those where the boom orientations are off to the
side of the carrier, small areas of stress concentrations exist. However, these areas of stress
concentration do not surpass the design criteria where the material must withstand at least a
safety factor of 1.5 against material yielding. Later, however, it will be found that this
conclusion is based upon a theoretically perfect CAD model where real world material effects
from welding/cutting cannot accurately be predicted.

Concerning the Upper Structure:


The load cases analyzing the upper structure pass the design criteria of a 1.5 safety factor. The
highest areas of stress concentrations exist at the support gusset just above the main lift cylinder,
but stress values do not exceed the limit of 66,667psi.

Concerning Bolt Shearing between the Carrier and Outriggers:


An additional load scenario was created after a prototype had been built due to the shearing of
bolts holding the carrier to the outrigger assembly. The rear outrigger plate (P/N 300-0278) had
warped in welding and when the assemblies were joined this plate did not sit flush on the
outrigger housing causing an unforeseen shearing load on the bolts. As a result of making the
corresponding changes to the FEA model, the results concluded that this new induced shearing
load was in fact greater than the allowable shear load of the bolts.

Although Finite Element Analysis (FEA) has become a widely used tool for engineering analysis and design, it cannot be viewed as a complete
substitute for testing. If reasonable doubt is present after performing engineering hand calculations and developing FEA models, controlled
testing should be performed with reasonable loads and boundary conditions applied.

Specialty Systems Engineering 121 N. 1st Street Montevideo, MN 56265 (320) 269-3227
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Table of Contents
Executive Summary ........................................................................................................................ 2
Table of Contents ............................................................................................................................ 3
Overview of FEA Modeling & Procedure ...................................................................................... 4
Definition of Boundary Conditions & Load Cases ......................................................................... 5
Carrier ...................................................................................................................................................... 5
Upper Structure ....................................................................................................................................... 8
Bolt Shearing ............................................................................................................................................ 9
Pass/Fail Criteria ........................................................................................................................... 10
Table of Results ............................................................................................................................ 11
List of Figures ............................................................................................................................... 12
List of Tables ................................................................................................................................ 15
Description of Loads Applied ....................................................................................................... 16
Description of Boundary Conditions Applied .............................................................................. 29
Detailed Loading Scenarios and Results....................................................................................... 31
Carrier .................................................................................................................................................... 31
Upper Structure ..................................................................................................................................... 82
Bolt Shearing .......................................................................................................................................... 90
Conclusion .................................................................................................................................... 98

Although Finite Element Analysis (FEA) has become a widely used tool for engineering analysis and design, it cannot be viewed as a complete
substitute for testing. If reasonable doubt is present after performing engineering hand calculations and developing FEA models, controlled
testing should be performed with reasonable loads and boundary conditions applied.

Specialty Systems Engineering 121 N. 1st Street Montevideo, MN 56265 (320) 269-3227
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