y

P=14.29 lb/in

L=14 in
R1 R2
Force equations for the given free body diagram:

(6)

Taking the sum of the forces in the y direction

(7)

(8)

(9)

100
Shear Force Diagram

-100

Moment Diagram

L/2 L

Figure 5: Free Body Diagram of Noseplate in Y-Z Plane with Distributed 400 lb Load
M eq =√ M xy + M yz
Force Analysis of Critical Components

In most situations, the hand truck is used to carry one heavy box from a delivery truck to the storage
area at Hampshire Dining Commons. In Figures 5 and 6, the loading situation is the most idealized case,
i.e. a 400 pound box situated perfectly in the middle of the noseplate. The noseplate’s weight is to be
neglected due to the minimal effect it will have in comparison to the weight of the box being carried.

Figure 5 is evaluating the noseplate head-on with the dimension of the front of the plate being 14
inches. The distributed load is estimated to be 28.57 lb/in which is a rounded estimate of 400 lbs/ 14
inches. The reactions, R1 and R₂, are equivalent being found to be 200 lbs each. Using the shear force
diagram, and knowing that the area under the force diagram is equal to the maximum moment of the
moment diagram, the maximum moment is 700 lb*in for this orientation.

Figure 6 is evaluating the noseplate from the side with the dimension of the side of the plate being 10
inches. Since the dimension changed to 10 inches, the distributed load changed to 40 lbs/in or 400 lbs/
10 inches. Given the plate's symmetry, this Figure will be used for each side. Also due to the symmetry,
the reaction, R, and moment, M, will be halved when determining the values for each side. This view
used a cantilever beam approximation in order to calculate all the values because the plate is attached
to the hand truck the same way a cantilever beam is attached to the wall. The reaction was found to be
400 lbs for both (200 for each side) and the maximum moment was found to be 2,000 lb*in (1,000 lb*in
for each side).

Looking at the part, it is clear the moments in the different planes all had an impact in fracture of the
noseplate from the hand truck. As Figures 1 and 2 show, the cantilever part of the noseplate has
completely fractured while the rest of the noseplate is still somewhat connected but visibly cracked.
Given that the greatest moment of the orientations occurs in the X-Y plane as previously stated, it makes
sense that the plate’s connection was completely fractured this way while only partially fractured in the
Y-Z plane which had a slightly lesser moment.
 Hand Truck Design
Force Analysis Midterm Project Report

By:

Brian Goss, Anthony Carloni, Jimmy McCarthy

Force Analysis Report Prepared for:

University of Massachusetts Amherst
MIE 313 – Design of Mechanical Components
Prof. Sundar Krishnamurty

Table of Contents
Hand Truck Design.......................................................................................................................................1
Table of Contents........................................................................................................................................2
Abstract.......................................................................................................................................................3
Introduction.................................................................................................................................................3
Project Objectives:...................................................................................................................................3
Plan of Work:...........................................................................................................................................3
Product Description and Operating Conditions:......................................................................................4
Force Model................................................................................................................................................5
Force Analysis of Critical Components.........................................................................................................7
Case I – Symmetric Loading.....................................................................................................................7
Case II – Asymmetric Loading................................................................................................................11
Future Work:.............................................................................................................................................18
Conclusion:................................................................................................................................................18
Appendix...................................................................................................................................................19
Abstract
A complete 3-dimensional CAD model was generated for an industrial standard hand truck dolly. The
failed part was identified at the welded joints that attach the structural steel pipe frame to the
noseplate. A series of force analysis calculations were conducted which show free body, shear, and
bending moment diagrams at the critical elements. Two different cases were investigated in order to
present a clear understanding of the internal forces that caused failure. Along with the two cases, the
group analyzed the force model of the entire assembly in static equilibrium at the instant at which
tipping is initiated, thus subjecting the joints to the maximum loading conditions. The minimum break
back force required to lift an estimated 400 lb load was found to be 51 lb. The first case looked at an
idealized loading condition of the hand truck, where the equivalent loading force is located at the center
of the noseplate. The maximum shear and bending moment were calculated for both the front and side
views and was found to be 200 lb and 1000 lb*in at each of the two joints. The second case determined
the internal shear and bending forces under asymmetric loading of the noseplate. Several graphs were
generated in Microsoft Excel which show how these forces interact as the equivalent loading forces
change along the x and y axis of the noseplate.

Introduction
Project Objectives:

The objective of this project is to analyze the Von Mises stresses of the failed components of a heavy
duty hand truck in order to present a new design that seeks to prevent localized failure at the welded
joints while minimizing weight and material usage. From an engineering perspective, the process of re-
designing this mechanical system will involve a thorough consideration of material selection, component
geometry, and load configuration. The net cost savings of the redesign can be expected to be XX
amount over the next ___years…

Product Description and Operating Conditions:

The hand truck is used to provide a mechanical advantage to its users through its double-welded
structural pipe frame, curved crossbars and 10 inch solid rubber wheels. This specific hand truck unit
has a height of 44 ¼ inches, an overall width of 19 ¾ inches and a frame depth of 21 ½ inches. The
noseplate, which supports the full bulk load, is measured as 10 inches by 14 inches and can hold up to
an estimated 600 pounds, according to the manufacturer Elkay©. The metal components of the
handtruck are made from 1030 structural steel that has a yield strength of 32 ksi and a ultimate tensile
stress of 62. Due to its robust wheels and ease of operation, the dolly is a simple and versatile machine
to control. It can be used outside or inside in all types of weather and temperature conditions.

This specific model was used at Hampshire Dining Commons by the work staff in order to transport
heavy boxes typically containing food freight and kitchen equipment from the distribution truck to the
dining facilities. According to the work staff, the hand truck provides a simple, convenient way to move
large shipments in a short turnaround time. In many cases, multiple boxes are stacked on top of each
other to reduce the number of loading trips back and forth. The boxes are almost always rectangular in
shape and packaged in a structured, uniform fashion by the food distribution company.

For an example of a typical loading scenario, consider square box containing 40 cans of tomato sauce. If
each tomato sauce can weighs around 5 lb, then an estimated 200 lb force is uniformly applied to the
noseplate during a lifting operation. In all subsequent calculations, a distributed load of 200 lb will be
assumed to be the average force on the noseplate. From the past 10 years at Hampshire, The handtruck
has been serviced an estimated 25 times per day (except in the summer when the dining common is
closed) to unload each morning shipment of food and supplies.

Redesign Strategy and Considerations

Under the loading conditions aforementioned, Figures 1 and 2 show the eventual failure that occurred
in both welded joints that connect the noseplate to the tubular steel frame. It is in this critical area that
the majority of the redesign process is focused. Using the force model and diagrams that were
developed in the previous report, the stress for the both the static and fatigue cases can be
characterized.

Figure 1 - 2: Photographs of left and right failed weld joint attached to the noseplate

In approaching the re-design process, a set of criteria was established to ensure that the new design
satisfies both the requirements of both the customer and the manufacturer. Adhering to this
philosophy, it was important that the new model (1) was designed for infinite life, (2) increased the
safety factor and reliability of the part, and (3) did not inhibit any aspect of its functionality.

In its current geometry, finite element analysis (FEA) was conducted using ANSYS workbench to identify
a single element that experiences the highest state of stress. It is reasonable to assume that this
element initiated fracture in the material, which then propagated and ultimately caused component
failure.
A series of tests were conducted in ANSYS that altered the current geometry of the noseplate in various
configurations. Material was removed in areas where stress was negligible and reinforced in areas that
experienced critical localized stresses, such that the net material usage was always maintained at zero.
Using this methodology, different configurations could be compared in order to select the best option
for a robust design with improved performance.
Force Model
The angles α and θ were calculated experimentally and assume values 60° and 25°, respectively. These
angles represent the most natural orientation when lifting heavy object with the hand truck and results
in the minimal break-back force F required to initiate tipping. At the instant the hand truck is tipped, the
normal force N of the noseplate is reduced to zero. The weight of the hand truck was measured to be
45 lb and its equivalent force is assumed to be located along the center crossbar aligned directly above
point O. Friction behind the two rubber wheels is considered to be negligible. Furthermore, geometry
symmetry requires that the reaction forces at the wheels are equal in value. In addition, it is assumed
that no translational movement occurs at the moment the hand truck is tipped backward.

The assumptions made simplify the force equation, such that there are three equation and three
unknowns. Through substitution we can simultaneously solve for the break-back force F, the reaction
forces R, and the leverage force P. The calculations are shown below:

Solving for P from (1) and substituted into (3),

Fcosθ (4)
P=
cos α

−200(10)+ Fsinθ ( 6.5 )+ Fcosθ ( 44.25 )− ( Fcosθ

cos α )
cosα ( 4 )=0 (5)

Combined equation (5) can be solved for F,

F=51.0 lb

Plugging this value in equation (4) gives,

P=92.4 lb

Using these values in (2) gives the reaction force:

R=273.3lb

The obvious advantage here is that for a 200 lb applied load, the hand dolly only requires a 51.0 lb
break-back force in order to tip and transport the load. As the hand truck is increasingly tipped beyond
its vertical position, the bulk load is removed less and less from the welded joints on the noseplate and
is distributed throughout its steel frame, crossbars, and spines. Therefore, it is deduced that the joints
take the maximum load at the instant the hand truck is tipped backward. Because the welded joints at
the noseplate are identified as the sole failed part, further force analysis of the hand truck at various
angles is irrelevant to the redesign and will not be considered in this report.
 M₂

W=200 lb

R₂

M₁

R₁

Figure 4: Model Noseplate with Equivalent Force Occurring at End of Plate

Force Analysis of Critical Components

In most situations, the hand truck is used to carry one heavy box from a delivery truck to the storage
area at Hampshire Dining Commons. In Figures 5 and 6, the loading situation is the most idealized case,
i.e. a 400 pound box situated perfectly in the middle of the noseplate. The noseplate’s weight is to be
neglected due to the minimal effect it will have in comparison to the weight of the box being carried.

Figure 5 is evaluating the noseplate head-on with the dimension of the front of the plate being 14
inches. The distributed load is estimated to be 28.57 lb/in which is a rounded estimate of 400 lbs/ 14
inches. The reactions, R1 and R₂, are equivalent being found to be 200 lbs each. Using the shear force
diagram, and knowing that the area under the force diagram is equal to the maximum moment of the
moment diagram, the maximum moment is 700 lb*in for this orientation.

Figure 6 is evaluating the noseplate from the side with the dimension of the side of the plate being 10
inches. Since the dimension changed to 10 inches, the distributed load changed to 40 lbs/in or 400 lbs/
10 inches. Given the plate's symmetry, this Figure will be used for each side. Also due to the symmetry,
the reaction, R, and moment, M, will be halved when determining the values for each side. This view
used a cantilever beam approximation in order to calculate all the values because the plate is attached
to the hand truck the same way a cantilever beam is attached to the wall. The reaction was found to be
400 lbs for both (200 for each side) and the maximum moment was found to be 2,000 lb*in (1,000 lb*in
for each side).

Looking at the part, it is clear the moments in the different planes all had an impact in fracture of the
noseplate from the hand truck. As Figures 1 and 2 show, the cantilever part of the noseplate has
completely fractured while the rest of the noseplate is still somewhat connected but visibly cracked.
Given that the greatest moment of the orientations occurs in the X-Y plane as previously stated, it makes
sense that the plate’s connection was completely fractured this way while only partially fractured in the
Y-Z plane which had a slightly lesser moment.
 y
P=200 lb
x

L=10 in

Force Equations for the given free body diagram:

R
(10)

Taking the sum of the forces in the y direction

(11)

(12)

(13)

200

Shear Force Diagram

Moment Diagram

-1000
L/2 L

Figure 6: Free Body Diagram of Noseplate in X-Y Plane with Distributed 400 lb Load
 y

P=14.29 lb/in

L=14 in
R1 R2
Force equations for the given free body diagram:

(6)

Taking the sum of the forces in the y direction

(7)

(8)

(9)

100
Shear Force Diagram

-100

Moment Diagram

L/2 L

Figure 5: Free Body Diagram of Noseplate in Y-Z Plane with Distributed 400 lb Load
Conclusion:

The hand truck was analyzed at the failed part of the mechanism in two different planes and two
different situations. The first situation was that the noseplate was subjected to an evenly distributed
load at the perfect center of the plate. Looking at it from the side and front gave different maximum
bending moments, which were calculated by finding reaction forces and corresponding shear force and
moment diagrams. The side bending moment was found to be 1,000 lb/in in each joint while the front
bending moment was 700 lb/in. The second situation was looked at form the same point of views, but
the loading was not as idealized as in the previous situation. The plate was analyzed using equivalent
point loads at varying locations along the plate. Worst case scenarios were when all the weight was at
any extremes, namely all on one side or farthest away from the joints. The second situation gave higher
moments for the worst case scenarios which more than likely caused the failure of the part with the
highest moment being 2,000 lb*in at a joint. Using the calculated forces, the model part can be
analyzed using ANYSYS and later redesigned against this failure.
From top left clockwise model of hand
dolly, mesh model of hand dolly, and
static structure of the hand dolly.
From the ANSYS the maximum stress
was found to be 17ksi.
Modified nose plate with the
least stress was the triangle,
followed by circle, square, and
diamond mesh.
Shape of the hole Max Stress (Psi)
Triangle 6843
Square 9337.5
Circle 7959.8
Diamond mesh 9744.6
The maximum stress in the modified hand dolly with triangle hole nose plate are 5316.6psi.