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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*
________________________________ Art Brooks, PPPL Engineering Analyst
Revie-e( )y*
_______________________________________
Mike !iola, PPPL WBS "iel# Perio# Assemly
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Cece( )y*
________________________________ Art Brooks, PPPL Engineering Analyst
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(+
i:
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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
(
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'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
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) *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'/
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Figure 3/ Lift !oint #* !ro'ecanica F0A Results/
Figure ;/ Lift !oint #* Ansys Eor9enc F0'/
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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/
)
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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
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Figure $/ Clevis & Lin !in 'o(el/
Shackle Pin
Link PinClevis
Actuator
Shackle Pin
Link PinClevis
Actuator
(*
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Figure / Station 3 Lift Clevis 1eo.etry/
Figure #%/ Station 3 Lin !in 1eo.etry/
((
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Figure ##/ Lug & !in Connection Failure 'o(es B$/
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
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(+
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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
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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
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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
(
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Figure #/ Non"Linear F0A Results G ;% ips/
Figure #3/ Non"Linear F0A Results G /= ips/
(D
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()
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#/ 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
(
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+(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*
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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(
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Appen(ix
e-er to -igure (F+F -or a22lying euations ('D5
0?uation #/ Allo-a9le !in 5ensile Strengt* B e? 3";=:/
eff
d
$t tb
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d
"
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Figure #@/ !in Sear & )en(ing 'o(el/
Figure #$/ !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
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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
+
==