Course: MEC3302

Assignment 4

Semester 1, 2012

Faculty of Engineering and Surveying, University of Southern Queensland

MEC3302 Computational Mechanics in Design, S1 2012 Assignment 4 Marks 300/1000 Due Date: 08th June 2012 Examiner: Jayantha Epaarachchi Moderator: Chris Snook

Assignment 4 consists of 2 questions. Student are advised to refer to Selected Reading Materials posted on the study desk in Weeks 8.9, 10 and 12 and MEC2402 Stress Analysis notes and the text book Beer & Johnston, Mechanics of Material or any Mechanics of Materials text book and HELP on ANSYS. You will be notified with any other details required for this assignment. All questions are to use the required report format which is published on the study desk of this course.. I will consider your own project for Q1 (only) if you can provide full details to me not later than 18/05/2012. Please note that your project needs the same level of complexity and suitability for FEA analysis as does the prescribed Q1 for it to be approved.

University of Southern Queensland

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Course: MEC3302

Assignment 4

Semester 1, 2012

Q1. (200 marks) A critical problem was identified in dump truck buckets working in an open cut mine. The problem was mainly caused by over loading the buckets with loading debris falling on the forward protruding canopy as a result of the loading operation. Cracks were found in the buckets protruding canopy and fatigue cracks were found on other sections as shown in the images of the truck on page 3. An engineer was assigned to investigate this problem and the following information was provided to him. Bucket dimensions and specifications. Some measurements of the buckets components supplied by the sites mechanical forman Due to un-even road surfaces it is assumed that bucket is experiencing 2.5g vertical impact loads frequently. Dump trucks also are experiencing 2g horizontal impacts frequently. Average density of the loads is 1900 kg/m3 Buckets are fabricated with 20 mm AS300 Grade structural steel sheets. Canopy loads can be taken as 1.5 Tons (evenly spread) and the bucket are overfilled by 15% of its rated capacity.

Assuming you were that engineer, perform the following tasks. 1. Create a suitable FEA model (Full or Half) for the Dump Truck Bucket on ANSYS. (50 Marks) You should try to use the given dimensions, specifications and operational details as much as possible. Use essential detail of the structural arrangements of the buckets such as bucket walls, stiffeners, supporting beams etc. You may use a substructure to investigate critical areas and finally justify your proposal with full or half model. Be careful to avoid unnecessary details of the bucket. Justify your assumptions thoroughly. 2. Perform relevant static analysis and investigate the problematic areas. You need to explain your load cases clearly. (25 Marks) 3. Show all necessary stress/strain/displacement plots for the original configuration. (15 Marks) 4. Suggest a modification using only additional stiffeners/tie-plate (gusset plates). Completing your modifications should not take the truck out of service for more than 1 day. (welding etc).(20 Marks) The modification should not have any adverse effected on the trucks operational capability. 5. Create an FEA (Full or Half) model of the bucket with your modifications and perform static and dynamic FEA analyses. With the aid of stress/strain/displacement plots, thoroughly describe the benefits of your changes due to your modifications. (70 Marks) 6. Explain how your modifications are likely to overcome the frequent fatigue damage. (20 Marks)

University of Southern Queensland

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Course: MEC3302

Assignment 4

Semester 1, 2012

150 mm x 150 mm x 8 mm SHS

Fatigue cracks found in these areas

150 mm x 100 mm x 8 mm U Channels

250 mm x 300 mm x 10 mm RHS 150 mm x 150 mm x 8 mm SHS

University of Southern Queensland

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Course: MEC3302

Assignment 4

Semester 1, 2012

(Specification sheets are available with the Assignment) University of Southern Queensland Page 4

Course: MEC3302

Assignment 4

Semester 1, 2012

Q2. (100 Marks) Perform an FEA for functionality of one of the following components. You need to do your own research and determine realistic/actual geometry/dimensions, the functionality/reallife use and the materials for your analysis. The functionality/real-life use must be clearly detailed in your report. You need to perform a static analysis and either steady state thermal analysis or modal analysis depending on their significance to the functionality. In your report, you must clearly show your estimate of input forces, temperatures etc. 1. A spur gear wheel (preferably 300 mm < PCD < 400 mm), hub has 5 spokes (not a solid hub), a 50 mm shaft drives the gear wheel and the shaft has an elevated temperature due to operational working conditions. 2. Propeller blade of an aircraft or a ship (preferably static (considering inertial conditions) and modal analysis) You may use sub-structuring, symmetry as required. 60% of marks will be awarded to description, modelling, assumptions and modelling techniques (mesh refinement, appropriate analysis etc.). Rest of the marks will be awarded for results presentation and discussion.

University of Southern Queensland

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