Optimum Life Expectancy of the Undercarriage parts of

Amphibious Excavators using Fatigue Failure Analysis

Abstract

Frequent replacement of equipment parts of the undercarriage of Amphibious Excavators causes

major losses (i.e. maintenance cost and expenditures, Equipment downtime) and delays on the
completion of dredging projects. The Fatigue Failure Analysis for determining the optimum life in
terms of cycles and /or years of the said parts (Track Shoes and Roller Chains) is presented.
Further, models of stress concentration simulations were experimentally investigated to establish
the fatigue life of the Track shoes made of High Density Polyethylene (HDPE) and Ultra High
Molecular Weight Polyethylene (UHMWPE) subjected to continuous and varied stress amplitudes.
Comparison between the two materials showed an almost similar reaction and length of fatigue
life. However, both materials were inappropriate as materials for the said part due to very life
compared to the equipment life span. Corrosion was also considered in the construction of the
fatigue life models of Roller Chains and Pontoons. The effect of corrosion greatly shortens the life
of the above – mentioned parts.

Introduction

Amphibious excavators (specifically DOOSAN 250AM, 140, 300) experience frequent breakdown
of track shoes and roller chains within a year of utilization. The common modes of failure of these
parts are cracking, bending, flaking, rusting and breaking after about 800 to 1000 hours of usage
(REMU data).

The amphibious excavator is one of the major equipment in dredging operations by the
Department of Public Works and Highways for Flood mitigation in different regions. This
equipment is used to transport silt, sand and other materials from a river, bank or coastal areas
in order to deepen or widen the channels and allow greater volume of water to flow. Amphibious
excavators can usually operate up to 5 meters of depth (defined by the arm’s length). It is a
specialized equipment which operates submerged in fresh water or marine water. The equipment
is supported by boat-like pontoons to keep it afloat and stable during operations. Along with the
pontoons is the track chain assembly composed of the roller chains, Multi-synchronous hydraulic
drive (MSHD) and Track shoes which are subjected to external forces that vary in magnitude and
frequency. The repetition of theses fluctuating loads, generates responses that differ depending
on the type of loading conditions and traction surfaces. The cyclic loads cause a cumulative
damage and cracks that can contribute to rupture the track shoes and roller chains. It is important
to make clear that the design and materials used for the track chain assembly have a problem
that needs special consideration. The frequent failure of these parts causing economic or human
losses will have direct consequences on the durability of the whole equipment.

Some research are being made to reconfigure the design of the undercarriage of the amphibious
excavator along with the exploration of material that can withstand extreme load and corrosive
environment.
The aim of this paper is to determine the optimum life or the ideal period for the replacement of
undercarriage parts through analysis and evaluation of its fatigue behavior. Prediction of different
models were carried out and compared to different available materials. Then, another model is
used which employs the effect of corrosion on the affected parts.

Material and Experimental Procedure

1. Load Computations

Image 1. Undercarriage parts (DOOSAN Infracore pamphlet)

The overall load was computed based on the existing data from the equipment specification and
approximation (dimensional computation) of the parts that were not included in the specifications.
The total load is the basis of all the stress computations of the parts to be analyzed. The following
is the breakdown of the load of the amphibious excavator:

Mass (kg) Weight (N)

Weight of the Excavator 21,600 211,823.64
Weight of Pontoon 8,500 83,356.53
Weight of Track Chain Assembly 8,200 80,414.53
Weight of Load (max) and Operator 1,070 10,493.12
TOTAL 39,370 386, 087.81
(Note: the above list are estimated values close to the actual value of the equipment during operation)***
The excavator which grosses to 21,600 kg (as per Specification) is supported by two pontoons
set at 2.71 meters apart. The overall load is distributed uniformly among the 19 tracks on each
pontoon by which sets vertical axial loads at 10, 724. 66 N. This is the load exerted on a single
track shoe on a flat cemented ground. While during operation, the traction exerts a horizontal
load of 74, 281.6 N.

6, 813.63 Newton / meter

R Rc R
Figure 2. Free-Body Diagram of Track Shoes

The track chain assembly consists of three strand roller chain. This allows the track shoes to be
supported at three different points, thus if considered as a beam becomes statically
indeterminate. This means that the load is concentrated at the center. The following load are
computed during no traction;

Rc = 5qL/8 where q is the distributed load, L is the total length of the track shoes
Rc = 6, 702.9 N
Rc + 2R = qL; R = (qL-Rc)/2
R = 2, 010.88 N

The same computation can be made with the resultant of the traction load and static load among
the three strands. Thus, the load is concentrated at the middle strand. The load at the roller
chains is computed as follows;

Lmiddle = 46, 907 N

Lsides = 14, 072 N

2. Modelling and Simulation

The body and dimensions of the track shoes and roller bearings were modelled using AutoDesk
inventor. The simulation is also conducted using the same software to compute for the Von-Mises
Stress. These stress concentrations are used to determine the fatigue life of track shoes made of
High Density and Polyethylene (HDPE) and Ultra High Molecular Polyethylene (UHMWPE). The
model was constructed based on the actual measurements of the track shoes to get a more
accurate result during the simulation.

Figure 3. 3D Model of track shoes attached to a three strand roller bearing.

Figure 4. 3D Model of the roller bearing

 Roller Chain Dimensions
Inner Outer Hole
Width Length Thickness
Diameter Diameter Diameter
(mm) (mm) (mm)
(mm) (mm) (mm)
Roller 35 80 30 --- --- ---
Link plate --- --- 60 200 16 6
Link support plate --- --- 30 100 14 6
Bushing 16 35 --- 30 --- ---
Pins --- 16 --- 62 --- ---
Table 1. Dimension of the roller chains

After the modelling of the track shoes, pin restrictions were made at the bolted parts. Then, the
computed load is applied on the element. (Insert instructions on how to simulate using Auto
desk Inventor)

Figure 5. Von-Mises Stress Model of the Track Shoes at zero traction

The simulation at no traction displayed a maximum stress of 3.733 MPa at the notched areas
where the bolts are attached, specifically on the sides. Most of the stresses are concentrated
around the bolted area in the same manner when traction is applied. However, during the
traction the stress concentration spiked up to about ten times the stress of that in the static
simulation. The maximum stress at maximum traction is 39.33 MPa while at minimum traction
the stress generated is about 25.11 MPa shown in the figure below.
 Figure 6. Von-Mises Stress Simulation of track shoes HDPE at track shoes

Figure 7. Von Mises Stress Simulation of UHMWPE Track Shoes

3. Fatigue Strength of High Density Polyethylene (HDPE) and Ultra High Molecular Weight
Polyethylene

A. Track Shoes

According to Chateauneuf, et. Al, from Statistical Analysis of HDPE Fatigue Lifetime, HDPE
Structures such as pipes is recognized to show a large scatter. The graph below shows the
distribution of Fatigue Life in terms of cycles over the Stress applied on the structure. The median
rank, the maximum likelihood and the Kolmogorov-Smirnov fitting are compared for the
estimation of the Weibull parameters. The choice of the best distribution to fit fatigue lifetime is
discussed on the basis of the goodness-of-fit results. It is found that whether the three parameter
distributions of Weibull and lognormal types are suitable for lifetime prediction, the two-parameter
Weibull is more conservative for probabilistic fatigue design.

The model below is used to compute the fatigue life of the HDPE Track shoes of the amphibious
excavator given the stress results based on the Von-Mises Stress simulation from Autodesk
inventor.

The S-N curve is defined by the equation NS8.6=6.7x1014 where N is the number of cycles and S
is the Stress Amplitude. During maximum traction, the stress amplitude is computed as 19.55
MPa which gives the least number of cycle at 5, 037 cycles. The maximum stress at this point
exceeds the yield and ultimate strength of the plastic (Appendix) thus, it is expected to instantly
deform and fail.

Figure 8. Fatigue Results and S-N Curve from Statistical Analysis of HDPE Fatigue Life

At minimum traction, the average stress or stress amplitude ranges up to 10.866 MPa, increasing
the capacity of the structure to tolerate the cyclic loads up to 823, 901 cycles. To determine the
minimum average cycles that the track shoes could endure, the logarithmic mean is derived,
giving a minimum average life of 138, 490 cycles. The maximum average life is derived from the
arithmetic mean of the two extreme cycles giving 414, 469 cycles. With the assumption that each
cycle is proportional to the angular displacement of the track shoes around the pontoon, it would
take at least 20 meters to complete a cycle thus, the average life of the track shoes ranges from
3,000 km to 8, 300 km. The amphibious excavator based on the Manila Bay Dredging operation
travels a minimum of 10 km per transporting dredge materials within a few kilometers to and
from the spoil site. With continuous operation over a year, the average working days would be
equivalent to 250 days. Thus the optimum life of the track shoes is computed to range between
1.13 and 3.14 years.

Figure 9. Fatigue Life of UHMWPE

Given the model of Fatigue Life of UHMWPE from the study conducted by Medel, Francisco J, et.
Al Chapter 30 “ Fatigue and Fracture of UHMWPE” of UHMWPE Biomaterials Handbook 2nd Edition.
The clinical significance of the fatigue and fracture properties depends on the prosthetic device.
The fatigue resistance of UHMWPE is now widely accepted as critical to the structure performance
of orthopedic implant bearings, and such data are now commonplace in regulatory approval
submissions. With regard to fatigue properties, both the total life (stress analysis based) and
defect tolerant (fracture mechanics based) approaches have been employed to characterize
conventional and highly cross linked UHMWPE materials, although the limitations associated with
total life experiments have rendered fatigue crack propagation experiments prevalent. The aim
of this chapter is to provide a theoretical background on fatigue and fracture concepts, as well as
the different philosophical approaches and experimental techniques available with special regard
to UHMWPE. It also outlines the main findings on fatigue and fracture properties of contemporary
medical UHMWPEs.

The fatigue life and stress relationship is defined by the equation as shown in the figure
S = 26.3 – 2.38log(N) where S is the Stress amplitude and N is the number of cycles.
The stress generated from the simulation in figure 7 is a maximum of 37.38 MPa during maximum
traction and 21.83 at minimum traction. The average stress is 18.7 Mpa exerted on the track
shoes. By using the same method of computing the range of life expected for a UHMWPE, the
result is slightly greater than that of the HDPE at 335, 902 cycles to 468, 040 cycles. This is
equivalent to about 7, 053 to 9, 800 km (2.67 to 5.7 years).

B. Roller Chains

The operation of the amphibious excavator in submerged areas greatly weakens the roller chains.
Its design contains many free spaces that are vulnerable to scraping and abrasion attacks from
foreign materials that insert into the material.

A 3d model of the roller is constructed using the Autodesk inventor to allow for simulation of Von-
Mises Stress. The dimensions of the structure are given in Table 1. The material used is Stainless
steel as this is the most common steel used to prolong or prevent itself from rusting.

Figure 10. Von Mises Stress simulation of pin (left) and roller bearing (right)

The simulation showed high value of stress (80.63 MPa) at the pins where the lock is located
while the roller bearing only showed 3.753 MPa radially. Using these stresses, the fatigue life
can be calculated from the graph given in the figure below.

From an ANSI perspective, the design of roller chains are generally based on 5,000 hours to
10,000 hours of life which would last to about 4.8 to 7.2 years. This is the most ideal life of
roller chains.

Due to corrosive marine environment, the fatigue life of the roller chains is degraded to 3,000
km to 6, 000 operating hours or an equivalent operating year of 1.44 to 2.88 years (reference:
Machinery lubrication, Chain Lubrication best practices for drives and conveyors John L. Wright)
Figure 11. Comparison of proposed S-N Curves with experimental test in air and saline water for
0.16 % Carbon Steel

Design Factors

Summary

1. High Density Polyethylene is not adequate enough to support the operating load of the
amphibious excavator. Its average life only constitutes to 1.13 to 3.14 years (30% of the
equipment’s life). The reinforced plastic is predicted to instantly deform at 5, 063 cycles
and then eventually fail. The same behavior is also observed on Ultra High Molecular
Weight Polyethylene (UHMWPE), but can sustain the operation to about twice that of
the HDPE. However, both materials are not recommended to be used as track shoes of
the equipment.
2. Roller chains is greatly affected by the corrosive environment and reduced the fatigue
life to more than half and will also fail in resonance with the track shoes at about 2
operating years.
3. The design of the roller chains does not support its continuous operation such as the
need for lubrication, and protection from corrosive environment.

Recommendations:

1. Metal has a higher value of material strength and can support the operation of the
amphibious excavator. Metals should also have strong anti-corrosion property in order to
prolong its fatigue life during submerged operation. (ADD MORE) hahaha