Finite Element Analysis Mast Assembly of Material Handling Equipment

 

A.T. Meshram

Nagpur Institute of Technology Nagpur

 

ABSTRACT:

The present work involved the optimization of fork lift mast design so as to controlled the deflection, maximum shear stress, von-mises stress, this work compare the stresses  in the structural steel and gray cast iron material for the same loading condition. The stress distribution has been analyzed using ANSYS 11 software for which maximum shear stress; equivalent shear stress at critical area has been calculated. Structural behavior of mast under loading and boundary condition using analytical model is very difficult. Therefore 3D solid model has been chosen in order to predict the detailed stress. 

 

 

INTRODUCTION:

Mast is a structural member it consists of one stationery member and one elevating member. This complete assembly attached with front side of fork lift truck for fast loading and unloading the material.

 

A number of researchers have work in the defined area. Some of the scientists investigate forward visibility of mast it is important of fork lift operation namely loading, unloading, and travel the new cross-section of mast rail has been develop to increase the inner width of mast so front visibility has been improve 6% with 2- stage mast and 14% with 3-stage mast [1] .

 

The industry forever change The Toyota  SAS was first introduce on 7 series it is an electronic control system which automatically observe and control over 3000 key function.

 

However to have greater productivity and speed fork lift are designed with tall mast [2].

 

To increase the Vision system composed of an OCD colour camera and frame grabber installed in a PCI slot of Pentium 120 PC provide the path every 100 ms which allow the industrial truck to be steered at its maximum speed 10 m/s  lift truck also operated with integrated RFID hardware can developed in warehouse IT system [3].

 

It may focused on the use of CAD software some researchers invented tip over stability analysis of a telescope fork lift truck .the stiffness of the chassis FEA model using ADAMS / FLEX then analysis of this model in NASTRAN software[4]. Study the failure rate and design alternative for stand up fork lift truck design the door as per the SAE standard for low lift and high lift industrial truck by using the Pro/ Engg  make a model and analysis of using statistical analysis software MINITAB[5]. Also steer-by-wire system was developing in 2003 [6].

 

Based on the literature survey, it was found that problem in the mast during lifting the load .The maximum shear stress Equivalent (Von-Mises) stress, Deflection on the mast. the present work optimization of fork lift mast by using the Pro/Engg software and analysis on ANSYS 11 Software also concentrated on minimum changes in the geometry of mast then find out the stress distribution on the model then compare the both model and find the stress value of both the model.

 

 

 

Figure 1 Fork lift truck

 

Figure 2 Assembly Model

 

Figure 3  Stationary Member

 

ANALYSIS:

The following are the basic steps followed in anysis using ANSYS software which is use finite element method ( FEM ) as an analysis tool .

·        Building of Model : A 3D model of  fork lift mast is developed Figure 2 show the assembly of the mast and Figure 3 show the stationary member of mast.

·        Defining element type Each element type had a unique number that define the element category in the present work,a structural solid (10nodded tetrahedral element ) was taken.

·        Defining the material properties structural steel selected as a material of mast .its properties are given in Table 1 and  another model select a material as a gray cast iron its properties are given in Table 2.

·        Discretization mast model is divided in to number of part using 10-nodded tetrahedral elemnents. The discretization of mast in the present cast is shown in Figure depending upon the requirement of accuracy of results the fitness of mesh was varying. More finer was the mesh more accurate were the result.

·        Boundry conditions: the full load was taken  at the upper portion of mast  and it is fix at the bottom support .the maximum load applied is 78480 N as shown in Figure .

·        Solver:Solver was used to solve the simultaneous equtation that the finite element method generates. The result of the solution were the nodel degree of freedom values, which form the primery solution and the derived value, which makes the element solution.

·        Postprocessor:Postprocessing means reviewing the result ofthe analysis. It was probabily the most important step in the analysis as it tells how the applied load affect the design, how good is the finite element mesh, the value of the stress in the region and so on.

 

Table  1 the properties of structural steel

Properties                                           Values
Young's Modulus	2.e+005 MPa
Poisson's Ratio	0.3
Density	7.85e-006 kg/mm³
Thermal Expansion	1.2e-005 1/°C
Tensile Yield Strength	250. MPa
Compressive Yield Strength	250. MPa

 

Table 2 Properties of Gray Cast Iron

Properties                                            Values
Young's Modulus	1.1e+005 MPa
Poisson's Ratio	0.28
Density	7.2e-006 kg/mm³
Thermal Expansion	1.1e-005 1/°C
Tensile Ultimate Strength	240. MPa
Compressive Ultimate Strength	820. MPa

 

Figure 4 Mesh Model     
            

Figure 5 Fix Support

 

Figure 6 Applied Loads

 

Figure 7 Equivalent(Von-mises) Stress

 

Figure 8 Maximum Shear Stress

 

Figure 9   Deformation 

 

Figure 10 Equivalent(Von-Mises) Stress

 

Figure 11  Maximum Shear Stress

 

Figure 12   Deformation

 

MODEL 2 GRAY CAST IRON MINIMUM CHANGES IN GEOMETRY OF MAST STRUCTURAL STEEL MODEL

 

            Figure 13 Mesh Model

 

Figure 14 Equivalent (Von-Mises) stress

 

Figure 15   Maximum Shear Stress

 

Figure 16   Deformation

MINIMUM CHANGES IN THE GEOMETRY OF MAST GRAY CAST IRON

Figure 17 Equivalent Stress

 

Figure 18 Maximum Shear Stress

 

Figure 19 Deformation

 

RESULT AND DISSCUSION:

By comparing the both model of mast by using Pro/Engg software and analysis using in the ANYSYS 11 software analysis. the model first we used  the material structural steel this is model no 1and Gray cast iron model no 2 find the Equivalent stress, Maximum shear stress, Deformation.

Then remove the one member of original structure of structural steel model then find out the Equivalent stress, Maximum shear, Deformation.

 

Then remove the one member of original structure of structural steel model the find out the Equivalent stress, Maximum shear stress, Deformation. Then similarly remove one member of original structural of Gray cast iron then find out the various stresses here we present graph.

 

Fig.20  Minimum and Maximum Equivalent Stress Model 1 and  Model 2

      

Fig.21 Minimum and Maximum  Equivalent Stress (Model 3 and  Model 4)   

 

Fig.22 Equivalent Stress Vs Shear stress Model 2 and  Model 3

 

Comparing the Equivalent Stress Vs Shear stress of model 1 and model 2 in the Gray Cast Iron Stress is more as compare to the structural steel.

 

Show that Compare the value of Equivalent stress Vs Shear stress of model 3 and 4 in these model we do minimum changes in the geometry of mast as compare the Model 1and Model 3 Stress value nearly same. Also compare the Model 2 and 4 Stress value nearly same

 

Table 1 comparison of values of   maximum stress and minimum stress 

Name	For Load = 78480 N Model No1		For Load = 78480 N Model No 2
	Mini	Maxi	Mini	Max
Equivalent Stress	6.88 Mpa	24.394  MPa	2.20×104     MPa	34.58  MPa
Shear Stress	3.5608 MPa	13.641  MPa	1.2×10-4    MPa	19.73 MPa
Deformation	0mm	0.227mm	0mm	0.4022 mm

 

Table 2 comparison of value of    maximum and minimum stress

Name	For Load = 78480 N Model No 3		For Load = 78480 N Model No 4
	Mini	Maxi	Mini	Maxi
Equivalent Stress	3.6 ×108-  mpa	24.434 MPa	1.4 ×10-4  MPa	34.895 MPa
Shear Stress	1.9571 MPa	13.704 MPa	8.2×10-4 MPa	19.916 MPa
Deformation	0 mm	0.4310 mm	0mm	0.7578 mm

 

CONCLUSION:

By the optimization of mast member and give the better material for Industrial application. Present study deal with Pro/Engg. Wildfire 0.3 and ANSYS 11. here we consider the stationary member of mast in structural steel ( Model 1) and gray cast iron (model 2) as compare the both the material stress developed in the Gray cast iron model is more. If some changes in the geometry of structural steel (model 3) and Gray cast iron (Model 4) value of stress is same. Hence according to the FEA result structural steel is useful for fork lift mast member for sustaining the load of 8 ton. 

 

The design and evolution and selection of mast which is use in the fork lift a worthwhile challenged to the engineer.

Now days a lot is being said about vibration study of mechanical component important role in its failure. The effect of vibration of mast on the engine is not considered in the present study and fatigue analysis.

 

ACKNOWLEDGEMENT:

The authors would like to thank Dr. V.T. Ingole Principal, Prof. Ram Meghe Institute of Technology and Research Badnera-Amravati, Dr. L.B. Bhuyer and Prof. S.G. Bahaley for their helps comments and suggestion, which improve the work done in the paper.

 

REFERENCES:

1.       H. Yamamoto and S.T akahara ‘Engine Powered Forklift Truck 1- to 3.5-ton’. Series LEO NXT – V’. Industrial Products, Vol.51, no 115, 2005, 

2        Toyota Industrial  Equipment September 2007.

3        F. Javier, M. Mazo and   M.A. Sotelo ‘ Automation of an Industrial fork lift truck Guided by Artificial Vision in open environments’ Autonomous Robots, vol.5, 1998. p 215-231.

4        R. Santos and D. Riesland ‘Tip-  Over Stability Analysis of a Rough Terrain Telescoping forklift”.North American MDI User Conference, 2001, p 1-13.

5        S. Jagar Lamudi.’ Failure Rate Studies and Design Alternatives for Standup Forklift Truck’. 2004.

6        Hiroyuke, B. Makoto, “Development     of steer-by-wire system for forklift truck, ”Toyota Industrial Technical R     eview.Vol.1, No.44, pp.35-39, Japan, 2002.

 

 

 

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