0% Gt OF 21 94 S14 os ch tr 2 ie dav avp7 “SIy WoLwaA TEKS WO¥d SY 3II0Y so TTDNW: @ 7 NaWs WISE SHS NO INGwiwsdxs ava TON HdVaD| STNSwaavaasia Tans NO. TNGWSd¥s SVTIn bed frame design, the main important aspect is the fixing of sectional dimension of main beams on whith bearings are fixed. Normally following ere the different type of loads acting on a bed frame which are to be con~ sidered. The total support reaction load which is coming on tyre will be distributed on two rolles at 30° incli- nation from central line of kiln. This distributed load can be spélit into two components i.e. one is the Vertical force acting on the bearing base which inturn will be transmitted to base frame. The second is the Horizontal force which acts along with base frame beam towards takeup Screws I. YEHTICAL LOAD ON BEARING BASEs This can be taken as uniformly distributed load over the length of bearing bases. In practices we are providing five square bars under bed frame ise one at the centre of bed frame two numbers at bearing centre lines and two numbers on both ends of bed frame. During final assembly, these square bars will go into the grouting and base freme will rest on these bars before setting off the grouting. But in design as~ pect to be on the safe side, we are considering only three square bars i.e. one at centre of bed frame and one each under bearing centre line as a supports. On the 32/-otherhand we are also not considering the fact of base frame grouting in design caleulatons. CASE: 1 By taking bed frame side beams as a continuous beam with three supports and over haging on both ends, we can represent this as below. i i As considered above the vertical load of bearing can be taken as distributed load on bed frame over the length of bearing base at both bearing points. In this case the maximum Bending, Fixing moments, Deflection of beam and stresses due to moments are to be found out. CASE: 2 We can take that no bending occurs in bearing base plate 'A' and beam top flange "BY since the BRG.LoAD plate thickness of ‘At in general considera~ ply high. So under bearing the vertical pearing load has to be taken by two verticel webs 'C' through top plates A & B as a compre- ssive force. The thickness of web 'C* should be sufficient enough to avoid we-b buckling and to keep compressive stress within the limits. 33/-as IL. HORIZONTAL FORCES: Since the support reaction is distributed on rollers at 0=30° indignetion from centre line, this produces @ horizontal force which can be assumed acting along with the surface of frame towards the take up screws, so basically first bearing fixing bolts and takeup screws should be designed for shear force and compressive forces respectively. when the bearings are firmly bolted to bed frame, these horizontal outward forces at bearing bases will result ‘the bed frome beams in tension and so beam sections should be designed to take up these tersional forces. The practical field there are some possibilitics of hell getting deformation during the operation ise, occurances of permanent shell sectional ovelity or longitudinal bending at support station or nearby etce ‘At these time one way of making shell into its original state is by pushing the support rollers of the station at which these effects ocair, towards the centre of bed frame for giving extra force on shell in the opposite direction. If we take this point into consi- derotion, the extre horizontal forces (tensional forces due to this also to be included) 34/-=-34- Tt. BEARING THRUST FORCE ON BED FRAME: This force acts prependicular to the above hori- zontal force in the same plen at bearing position as shown in the above main sketch. This thrust force can be due to two ways. First one is due to axial forstoming on to the roller sheft because of the frictional effect between tyre and roller which opposes the free downward movement of kiln due to its slope during running. The second one is the thrust force due to self load and inclination of Kiln. If we want to make the kiln to move upward direction, the frictional force between tyre and rollers ) (say by slightly tilting the axis of rollers) has to bé jnereased i.e, it should be more than the kiln self thrust force. So the actual maximum thrust force cen ‘be \ taken as the total of the self thrust and frictional } forces CASE: 4 This combined thrust force comes directly on roller shaft as axial force which transmits as thrust load on thrust washer of upward bearings of a support stations So this combined thrust force of bearing may cause base frame beam on which bearing is seating to @ twisting effect as a whole and some times bending effect on top flange of beam, Since the tope flange under bearing will be having extra ribs on voth sides the bending effect can be neglected. But the main aspect 4.0, shear stress due to this twisting moment has to be within the limits. 35/-= 35= CASE 5 Due to this combined thrust force at bearing postion, there may be possibilities of frame beam bending inside ward direction as shown in the following sketch. B c Let A,B,C,D,E,F are foundation bolt position and G,G' are the one side bearing positions which cause side force on the beam, In this case the cross beams can be taken as support positions and max. bending stress can be calculated at point G or G'. Iv. STABI) )F_BED F! SSEMBLI! ERECTION: During assembling and erection it may be necessary to lift the complete assembled bed frome i.e, with support rollers, shafts, bearings etc. by crane with lifting ropes tieing at extreme ends 2s shown in the sketch, So the bed frame should be stiff enough to have stress and deflections within the allowable limits. CASE: 6 We can take into consideration, two types of loads on bed frame which cause the defection during lifting. The main important one is the self load of pase frame i.e. its own weight which can be taken as uniformly distributed load through out the length and +36/-next load due to item coming over base frame i.e due to 4 { Rollers, Roller shafts which can be considered as point loads at bearing bases, Supports to be taken at extreme ends as shown above. So max bending stress and defle~ ction due to above two effects have to be calculated. MoIE:: The roller bed frome has to be designed always to take up the maximum station bearing (4 bearings) allowable load at its capacity. For design aspect we can consider the bed frame beam sections as a box section and projected flanges, verti- cal ribs under bearing base plates can be neglected. Following is an example which gives mode of basic cal= culations. EXAMPLE; Gince the load will be distributed on the both main beams of frame equally, for finding out the main sec~ tional dimensions, one side beam can be taken into account for calculation purposes+ 37/--37- (Ref: Bokaro Kiln bed frame) Bearing size = $ 400 x 525 mm Station capacity = 295 Tonness Total Load on bed frame including weight of bearings, shafts, rollers = 315 Tonnes. Load coming on each beam = 157.5 Tonnes. Bearing base length = 1000 mm, 3 3 Modules of Section z = BY gpbibt = 232 x 960%. 200 x 508? ie (oJ = (4,08 = 2063) x 10 Lear x io'm? x 3 = 0,00432 M a Moment of Inertia Z _ a = 3 6, 1 = bho = ban? = 4,32 x 10°x560 T. = 1209.6 x 10° mn* =0.0012096 w* 38/-Modulus of Elasticity E 21000 Kgs /mn* CASE; 1 Vertical Load at bearing base: pearing load taken as UDL over the length of its bese say 78475 Tonnes per 1000 mm length at two position on supports (Sequar bars) 1 & 3 as shown in the above sketch, Fixing moment at support 1 due to ist UDL = 78.75 x 0,55 x 06275 = 11.92 Ton Meters. In this type of loadingdiagram, the BM will be always less than FM at supports which are identical at both 1 and 3 supports. vt Max. Bending stress = 1000 x 1000 x 1192/4432 x 10° =2.77 Kgs/mn™ CASE: 2 Compressive load on Vertical Webs: As envisaged in the above assumptions, the vertical pearing load will act as compressive force on both vertical webs which are under bearings Sinde both vertial web ends are welded to top and bottom flanges of base frame, we can consider the top and bottom edges as clamped and side edges re simply supported for finding out critical unit compressive stresses (Ref: Case A-6, Page 312 of "Stress & Strain" by RiJ.Rark)« 39/-2396 Critical unit compressive stress: 4 =S'=K re { = } Ge > where K = factor from table - say 12.0 at a/b ratio of 0.508 E = Modulus of Elasticity = 21,000 Kgs/nm* Y = Poissons ratio = 0.3 + = Thickness of plete (16 mm each) = 32 mm total b = force acting edge = 1000 mm. . ss 12,0 x ARS ay =x BRR 0.001024 2 294 Kgs/am@ Actual compressive stress s = 78.75 x 1000 = 2.46 Kgs/nm? 32x1000 GASE;3 Tensional rane due to ces. Total station 4 load (indluding Roller, Shaft etc) = 315 Tons. Load coming on egch bearing set } 315 = {iwo Nos) at 30° indice tion } -P- = 102 Tons. aring Horizontal + Horizontal pulling force by two bearings =182/2=91 Tons. Sesticnel | area of beam which is ecg tension = 200 x 20 + 200 x 32 + 560 x Stress due to tension = 91000/28320 = 3,22 Kgs/am” CASE:4 Frame twisting due to kiln thrust forcese 40/-s | | Horizontal sideward thrust: © | = 295 x 0,155 = 45.8 Tonnes. ig Le a \ where 0,155 isthe factor we are oH ig using normally for calculatins ana ~<— upward and domnvard forces. — Thrust force due to its self load @ = 295 x 0,035 = 10,325 Ton where 0,035 is because of 3.5% slope. +. Max, thrust force can be :O+® = 45.8 + 10.325 = 56,125 Tonnes. «s On each roller = 28,0625 Tonns. Twisting moment for hollow rectnagle) (Ref: Page 176 of stress & strain by RJ Roark & tere tel6, 7” 2tt,(a-t)*( bet)? ay +H Stk =a ae 2 at + bt - t =t,2 : ] 4 | || Say t= 16 mm tk. +)=(20+32)/2=26 mm : a: 232. 2, 2 x16x26x( 216 4 KBR I Ste oe? 3 = Lago? = 6.34 x 10°nma, Twisting moment ‘Tt =2820625 x 0.280 + 7.587 Tan Meters. Shear stress '9 2t, (a-t) (b-t1) near middle,length of Horizontal webs. = 7,857 000 {000 a Tewke =I8 (360-26) 41/-ara = 1,987 joo, 1000 =1.31 Kgs/mm* x 216 x CASE: 5 Bending due to thrust force on beam a Sectional Mogulus ‘2! = 3 q = 56 x 22329 = .s08 x 42° a 2 3 Bs 42560 | Sa = 0.00212 mM? Assuming foundation bolts OR cross beams act as rigid supports for the beam coming between Crosse. »5..625) beams. BoM Max. = gE = 28,0625 2.6 |, _Lssei—f 2600 8 = 9,11 R Ton Meterss Bending stress = Seb 24,3 ygs/an? £6 Effect of assembled bed frame while ASE lifting during erections This is to find out the stability and stiffness of bed frame while lifting during assembling/ erection periods. In this we can find out stresses and deflections in bed frame due to (4) its own self weight which can be taken as UDL throughout the length of fame (ii) due to weight of Rollers, shafts, bearings as concentrated loads at each bearing position. 42/-5 T7ealuD R11 9,900 9 300 x 400 aot p 500 55/65 p 120 p 220 p 250 330 ¢ 480 250 280 pias # 900 # 300 x 400 g a4 to $ 1400 $ 400 x 525 30° p 800 100/120 # 230 ~ 370 p 420 B 540 g 7130 375 55 a g 1900 g@ 500 x 640 sot 9 950 135/160 p 315 p 475 p 525 9 665 ~ 880 450 70 515 933 g 2300 @ 625 x 715 a @ 115¢ 180/21 g 390 gp 580 640 $ 800 $1050 550 640