Stress analysis of

Heavy Machineries:-
EXCAVATOR

MEMBERS:-
1.KRISHNA DESHMUKH
2.SHUBHAM KHOSE
3.SWARAJ PAWAR
4.ASHWIN VYAS
WHY DO WE NEED STRESS ANALYSIS ?
Performing a stress analysis is a great way for members of the
engineering and manufacturing industries to ensure their final
product is reliable.

A stress analysis is a series of tests that will help you see how the
materials and structures you create react under force or pressure.

Structural Reliability:-
This analysis helps you to determine the reliability of your structure.

You are seeking to learn how internal stresses are distributed

throughout a bridge system based on the external forces that act on
it. The strain is measured by how your materials deform while being
placed under these stresses.

In the example of a bridge, there are many different materials and

structural elements that make it work.

Bridges are also built to last.According to the American Society of

Engineers, the average age of a bridge in the United States was 42
years as of 2013.

As a bridge ages, it will need to undergo renovations and remodels in

order to maintain its structural integrity.But it's important that the
bridge is structurally sound from the outset. But there are a lot of
external forces acting upon a bridge.
Depending on the geographic location of a bridge, it will be well-
traveled and have to stand up to a range of different weather
conditions. If it's located near a major city or seaport, it may also be
responsible for withstanding years of abuse from heavy trucks and
other vehicles.

Through a stress analysis during the initial design, you can test the
different elements of the bridge.

This includes testing different load weights at multiple locations

across the structure. By performing these tests, you can see how your
bridge holds up to those external forces. This helps you to ensure that
your structure is safe and reliable.

Cost Effective:-
By using stress analysis on your structure, you can recognize issues
with your structure early in the design process.When you find issues
with the design or materials you are using, you can address these
early. This helps you to save time and money on the project that you
are working on. You may be using a design that isn't optimal for the
consistent load the structure will need to bear.

You could also be using materials that don't react as well to the
stresses they are put under. By performing a stress analysis, you are
learning the strengths and weaknesses of your structure.

This proactive approach means you will be better prepared to resolve

issues. As an engineer, you want to learn about any problems as early
as possible.This helps you to resolve them and limits the time and
money you spend going back to fix things after the fact. When you
catch these issues earlier in the process, you can address them and
still stay on track for your project deadlines.

The Importance of Performing a Stress Analysis

A stress analysis is an important series of tests that will help you and
your engineering team as you design and build your projects. As an
engineer, two of the most crucial elements of your position are
creating safe and reliable structures for your clients.

The stress analysis helps you identify where your structures are
meeting expectations and how you can improve on others. By
performing these tests you will build a structure with integrity and
that can hold up to the forces exerted on it each day.

You will also be able to correct any issues that arise early in a project.
This saves you from the frustration and headache that comes with
uncovering problems later in the building process.

When you pinpoint these concerns, you and your team can
collaborate to discuss them. Through these discussions, you can
develop effective solutions to improve your design. You can also
decide what materials will work best under the stresses and
conditions being placed on your structure.

INTRODUCTION :-
Excavators are heavy construction equipment
consisting of a boom, dipper, bucket and cab on a
rotating platform known as the house. The house sits
atop an undercarriage with tracks or wheels. They are a
natural progression from the steam shovels. All
movements and functions of a hydraulic excavator are
accomplished through the use of hydraulic fluid, with
hydraulic cylinder and hydraulic motors. Due to the
linear actuation of hydraulic cylinders, their mode of
operation is fundamentally different from cable-
operated excavators which use winches and steel ropes
to accomplish the movements
PARTS OF AN EXCAVATOR:-

PARTS OF INTEREST :-

1.SHAFT
2.BOOM
3.SPROCKET

SHAFT :-
A shaft is a rotating member usually of circular cross-
section, which is used to transmit power and
rotational motion in machineries and mechanical
equipment in various application. Most shafts are
subjected to fluctuating loads of stress concentration.

• BOOM:-
• The excavator boom is one of the key components
of an excavator, and also main load bearing part.
The boom of an excavator is a box shaped
rectangular section structure. The boom structure is
mainly made of thin steel plate welded together
which forms a complex geometry. Excavator boom
under the main frame is consist of four primary
plates viz., cover plate, under cover plate, left plate
and right plate excluding other supporting plates
such as front fork plate, Strengthening Plate, Boom
cylinder connecting seat plate, Arm cylinder
connecting seat plate. The shape and size of all the
plates vary from manufacturer to manufacturer.
Stiffeners and reinforcement plates are welded
inside to increase the strength and to prevent the
excessive deformation
APPLICATIONS OF THE EXCAVATOR:-
The main uses for an excavator are digging trenches, holes, and
foundations, providing the power to do these tasks much more easily
and effectively than any other piece of heavy equipment on the
market. Companies across many industries may be looking at
excavators for sale in North Carolina thanks to the wide range of
industries they are used for, including forestry, mining, and all types
of construction. In addition to digging, excavators are commonly used
for projects such as demolition, dredging rivers, material handling, or
just simply heavy lifting of objects.

With such a wide range of uses, it makes sense that there are
different types of excavators to help find exactly the right one needed
for the job at hand. One example is a tracked and wheel excavator,
which is perfect when the job calls for things such as digging, material
handling, brush cutting, demolition, open-pit mining, forestry work,
and much more. There are great for big jobs.

There are also mini excavators, which are smaller and lightweight,
which makes them easier to transport quickly and efficiently to
various construction sites. These types of compact excavators are
ideal for trenching, as well as a wide range of utility work. In some
cases, with the advances we have seen in hydraulic systems, these
smaller excavators can even outperform larger machines, pulling their
weight in a way that many people looking at heavy equipment for sale

1. Clearing — In wooded or overgrown areas targeted for

development, compact excavators can improve properties with their
ability to level dead or fallen trees and remove underbrush. Their
tracks help to provide access through thick vegetation and soft
terrain. Versatile attachments like midsize buckets with teeth, three-
tined grapples and rotating grapples can grab, pull and drag saplings
and rooted undergrowth, as well as sort and load material.

2. Park maintenance — All of the landscaping jobs performed for

residential or commercial properties are typically needed in municipal
and federal park maintenance. Buckets and grapples assist with
cleaning and clearing land and building campsites. Clamps move
broken concrete, brush, logs, tree stumps, boulders and other odd-
shaped objects — even old playground equipment. Grading blades
make great tools for rough or finish grading, backfilling and leveling.

3. Trail development — Constructing and maintaining the trail

systems and golf cart paths that are popular with recreational
enthusiasts is tough to do with most machines, but is easier with a
compact excavator equipped with a trenching bucket and grading
blade. Excavators are ideal for clearing and prepping paths measuring
approximately 5 feet wide with minimal disruption. These machines
increase their value exponentially by eliminating the alternative of
hand labor and shovels.

4. Landscaping/hardscaping — Anytime there’s a need to re-form

land, recreate an outdoor environment, or build an elaborate
hardscape, compact excavators with rotating grapples provide the
grasp. The wrist-like flexibility of a rotating grapple allows operators
to dig square holes, load/unload and sort material, move vegetation
and place landscape boulders and timbers. Tined grapples, paired
with a clamp attachment, are perfect solutions for handling timbers
and other dimensional lumber for a hardscape project like
construction of waterfalls and ponds.

5. Demolition — Excavators are perfectly suited to all phases of

demolition work with attachments like breakers, buckets, grapples
and clamps. Armed with these accessories, operators can tear out
concrete and asphalt driveways, sidewalks, trails, paths and
swimming pools. Knocking down small vertical structures such as old
buildings and retaining walls into manageable chunks is possible, too.

6. Site prep/grading — Prepping a site for paving or planting could be

done with your excavator fitted with a ripper to penetrate and scarify
frost and hard ground. An appropriate bucket will haul in aggregate
base material. Some manufacturers offer a tilt swing accessory that
mounts between the excavator’s bucket and the arm to help create
slopes, cut drainage ditches or contour soil. A grading blade can turn
an excavator into a rough or finish grader, as well as a backfilling and
leveling machine.

7. Compaction — An excavator can be fitted with a plate compactor

that is designed to compress soil from the top down, while a packer
wheel attachment can compact the fill from the bottom up. These two
attachments can eliminate placing workers in a trench to do hand-
operated compaction or managing a walk-behind unit above ground
to close up a trench.

8. Utility rehabilitation — With their versatility and ability to access

tight areas, compact excavators and attachments such as buckets,
grapples, grading blades and clamps are as effective in utility
rehabilitation applications as in new construction. With an aging
infrastructure, there’s a growing need to refurbish aging utilities,
specifically gas and sewer lines and septic tank systems. More
municipalities are also realizing the aesthetic and protective value of
burying overhead power lines.

9. Tree planting/fence posts — Fast and accurate digging with an

auger provides operators a quick method for installing fence posts,
piers and poles, or planting trees and other vegetation.

10. Reshaping earthen walls — With a growing emphasis on climate

change and wet weather patterns, many urban and rural areas are
seeing increased stress on dike and levee walls. With a grading bucket
and an extendable arm available on some compact excavators, walls
can be reshaped by pulling fallen dirt up to a levee’s top edge to re-
form the shelf. The soil can then be rolled downhill and sloped with a
swing accessory for improved mowing and spraying

ANALYSIS OF THE EXCAVTOR PARTS:-

SHAFT :-

Calculation of torque :-
T=P/W

W=2*pi*N/60

Where

T=torque

P=power

N=speed
Calculation for max stress:-
Ts =T*R/J

J=pi/32(do^4-di^4)

do=outer diameter

di=inner diameter

Ts= max stress

T=torque

R=radius

• Calculations of the shear stress:-

• Length of the shaft(l):-2.83m

• Diameter of the shaft(D):-0.265m

• Weight acting of each end of the shaft(W):-17,750 kg

• Bending moment(M):-Wl/8

• Moment of inertia(I):-(3.14*D^4)/64

• Using relation:-

• M/I=shear stress/y

• Therefore,
 • Stear stress=[(Wl/8)*(D/2)]/[(3.14*D^4)/64]

• =4Wl/3.14*D^3

• =4*17750*9.8*2.83/(3.14*(0.265)^3)

• =33697958.42 N/m^2

CALCULATIONS OF THE BOOM:-

• Calculation of max bending stress

Ts=M*y/I

Where

M=bending moment

y=distance of max stress

I=moment of inertia

Actual calculation at stationary state:-

 • F=45000 N

• D=8 m

• B=1.5m

• T=0.25m

• t=0.75m

• M=F*D

• I=(BD^3/12)-[(B-t)(B-2T)^3/12]

• Y=B/2

• Ts(max stress)=M*y/I

• I=(1.5*8^3/12)-[(1.5-0.75)(1.5-2*0.25)^3/12]

• I=6.3333*10^12 mm^4

• Ts=0.227 N/mm^2

CONCLUSION :-

The calculated values of torque and forces are most appropriate for
the construction of these parts of an excavator.

References:-
1.Research papers on excavator

2.Research papers of some excavator companies