Welding Machine

Rack
DESIGN REPORT
JEROEN OOSTHUIZEN

Contents
Introduction........................................................................................................... 2
Problem Statement................................................................................................ 2
Approach............................................................................................................... 2
Finite Element Analysis....................................................................................... 2
Assumptions....................................................................................................... 2
Payload, Tare Mass, Rating & Centre Of Gravity.................................................2
Design Process....................................................................................................... 3
Material.............................................................................................................. 3
Sling Set & Shackles........................................................................................... 3
Structural Sections............................................................................................. 4
Pad-Eye Calculations.......................................................................................... 4
Stability.............................................................................................................. 5

Introduction
This report was prepared and compiled to document the design process and
analysis for a welding machine rack which is to be designed to carry eight
Lincoln DC400 or DC655 welding machines. The rack will be used onshore, but
will be designed to be able to handle quite a large amount of abuse. The DNV
2.7-1 code for offshore containers was therefore used as a guideline for the
design of the structure. Designing according to this code will result in a strong
and reliable structure which will give no problems onshore, even when abused.

Problem Statement
A rack is to be designed to carry eight Lincoln DC400 or DC655 welding
machines for use onshore. The rack should be able to tilt 10 in both axes of
width and length without overturning. The rack should be designed to be
primarily transported by means of an overhead crane, but forklift pockets should
also be incorporated for possible forklift transport. The rack will consist of a
section containing the majority of the payload, the welding machines, as well as
an additional section to house the distribution box.

Approach
The design for the structure will start off with the DNV 2.7-1 code as a guideline.
The guidelines within the code for primary structure material, forklift pockets and
pad-eye calculations will be used for the preliminary design.

Finite Element Analysis

FEA will then be carried out on the primary structure and the design will be
refined according to the results of the FEA. An FEA will be carried out on the
primary structure when 4-point lifted, 2-point lifted, forklift lifted as well when the
structure receives horizontal and vertical impact loads.

Assumptions
The following assumptions were made throughout the design:
1.) All primary structure welds are full penetration welds and the structural
section, tubing and plates should be bevelled accordingly.
2.) 2mm weld gaps are used throughout the primary structure.
3.) The structure is to be used in temperate climates.
4.) The structure is strained within the linear range and the material is
therefore perfectly elastic.

Payload, Tare Mass, Rating & Centre of Gravity

1.) Payload:
The payload is the non-structural mass which the structure must carry. The
mass of the heaviest welding machine, the Lincoln DC655, is

327 kg .The

rack will carry 8 of these, therefore the payload is:

Payload=8 327=2616 kg

2.) Tare Mass:

The tare mass is the mass of the structure without the payload, therefore
the mass of the rack without the welding machines. The tare mass is
calculated as the CAD calculated mass of the welded assembly, plus 4% of

this mass to account for welding, plus the mass of the four securing bars,
plus the mass of the lifting set, estimated at

60 kg :

Tare mass=1446.41 1.04+48.067 +60=1613 kg

3.) Rating:
The rating of the rack is the sum of the tare mass and the payload:

Rating=2616+1613=4229 kg

4.) The centre of gravity of gravity for the rack with the welding machines
was calculated by means of CAD, and has the cordinates:

(x ; y ; z)(1837.2 ;1193.17 ;578)

Taking the front left corner at the bottom as the origin.
The y-component will be used to calculate the maximum tilt of the rack
and the x- and z-components will be used to calculate the lifting point the
sling leg angles. The x- and z-components of the centre of gravity with
respect to a lug point is:

(x ; z )(1675.22 ; 494.92)

Design Process
Material
All material throughout the primary structure will be S355JR grade mild steel.
This material has a minimum yield strength of 355MPa and impacts a minimum
of 27J in a Charpy test at room temperature.

Sling Set & Shackles

The centre of gravity with respect to a lug point is (x ; z )(1675.22 ; 494.92) .
The sling set for this rack will be asymmetrical due to the off-centre centre of
gravity. The vertical height of a sling set lifting point above the pad-eyes is:

x2 + z 2
H=
tan ( )
Where

and

are the coordinates of the centre of gravity and

is the

sling leg angle.

Therefore, for a maximum sling leg angle of 45 :

H=

1675.222 + 494.922
=1746.8 mm
tan ( 45)

For this height, the other two sling legs will have an angle of 38.6 .
From table 8-1 in the DNV 2.7-1 code, the minimum required Working Load Limit
(WLLmin) for a rating of 4229 kg is:

WLLmin =9.3 tonne=9300 kg .

The required working load limit for each

WLL45 =

45

sling leg is calculated as:

9.3
=4.39 t
3 cos ( 45)

The required working load limit for each

WLL38.6 =

38.6

sling leg is calculated as:

9.3
=3.97 t
3 cos ( 38.6)

The working load limit for the shackles are:

WLLs=

9.3
=4.39 t
3 cos ( 45)

Therefore, 4.75t Crosby style shackles will be sufficient for the design.

Structural Sections
150x100 rectangular section was chosen for the base of the rack, and 100x100
square section was chosen for the remainder of the primary structure tubing.
Using the DNV 2.7-1 code as a guideline, the wall thickness of the tubing was
initially chosen as 6mm, but after the FEAs a thicker wall of 8mm was rather
chosen. The mounts for the machines were chosen to be 60x60x8.0 angle iron.

Pad-Eye Calculations
The calculation procedure stipulated in the DNV 2.7-1 code was followed to
ensure that the pad-eyes (lifting lugs) are of sufficient strength. Initially, 16mm
thick pad-eyes were chosen, which was calculated as safe with the calculation
method below, but the FEA showed rather high Von Mises stresses in the padeye, so a thicker pad-eye of 25mm was rather chosen. The calculations below are
to show that the 25mm pad-eye is considered safe according to the DNV 2.7-1
code for tear-out and contact stress.
The resulting sling load (RSL) is the working load force exerted onto each sling
leg. The welding machine rack will have four lift points, two with sling leg angles
at 45 and two with sling leg angles at 38.6. The RSL (for a rating of

R=4229 kg ) on a 45 sling leg is calculated as:

RSL 45 =

3Rg
3 4229 9.81
=
=58671 N
3 cos ( 45)
3 cos ( 45)

The RSL on a 38.6 sling leg is calculated as:

RSL38.6 =

3Rg
3 4229 9.81
=
=53085 N
3 cos ( 38.6) 3 cos ( 38.6)

The larger RSL will be used in the design, RSL=58671 N . In the design of the
pad-eyes, the following criteria should be met:

Tear-out stress:

3 RSL
2 H tDh t

Contact stress:

23.7

RSL
Dh t

denotes the minimum yield strength of the pad-eye material,

Where

the shortest distance from the centre of the shackle bolt hole to the edge of the

Dh

pad-eye,

the bolt hole diameter and

the pad eye thickness.

1.) If S355JR is used as pad-eye material, the minimum yield strength is

=355 MPa .
2.) A 4.75 tonne shackle has a 22 mm diameter pin (table D-1), therefore,

D h is chosen slightly larger, at 23.5 mm.

3.) A pad eye thickness ( t ) of 25 mm is chosen. This thickness is also larger
than 23.25mm; which is 75% of the inside width of the joining shackle, as
specified in DNV 2.7-1.
4.)

is chosen to be 35 mm.

Therefore:
Tear-out stress:

3 RSL
3 58671
=
=152 MPa
2 H tD h t 2 35 2523.5 25

Contact stress:

23.7

RSL
58671
=23.7
=237 MPa
D h t
23.5 25

From the above calculations, it can be seen that the tear-out and contact
stresses are well below the minimum specified yield strength of 355 MPa of the
pad-eye material, therefore the above dimensions for the pad-eye are sufficient.

Stability
The requirement for the rack was that it should be able to tilt 10 without
overturning. The maximum angle of tilt of the structure is calculated as:

=arctan

Where

( wh )

denotes the angle of tilt,

of gravity in the structures width, and

w
h

denotes the component of the centre

denotes the component of the centre

of gravity in the structures height.

Therefore,

=arctan

578
( 1193.17
)=25.85

Therefore the rack is far within the specification of tilt.