Design and Analysis of Weight Lifting Pallet With Respect To Sandwich Pattern of Pallet

10 I January 2022
https://doi.org/10.22214/ijraset.2022.40130
International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 10 Issue I Jan 2022- Available at www.ijraset.com
Design and Analysis of Weight Lifting Pallet with

Respect to Sandwich Pattern of Pallet
Dr. V. A. Kulkarni1, Mr. Varun Patil2, Mr. Prathamesh Abhang3, Mr. Om Sankpal4, Mr. Aayush Pachpande5
1
Professor, 2, 3, 4, 5Student, Department of Mechanical Engineering, Dr.D.Y.Patil College of Engineering, Pune
Abstract: Sandwich plates are made of face plates which are separated by core material. They are usually designed in such a way
that the face plates carry the bending and in-plane loads, the face plates have relatively high stiffness and density. The core is
designed to sustain shear loads; it has relatively low density and stiffness. The face plates and core can be made from various
materials metals, composites, plastics, and organic materials but the core can also possess various topologies: a web, a
honeycomb. A structural sandwich consists of two thin face sheets made up of stiff and powerful relatively dense Material like
metal or fiber composite bonded to a thick light weight material called core. These structures are commonly used in lightweight
applications such as airplanes, marine systems and wind turbine instruments. Sandwiched panels have advanced High stiffness
and strength to weight ratio and during this work various sandwiched structure is applied to optimize the load of weight lifting
platform.
Keywords: Sandwich structures, Material Handling, Stress, Deformation, and Finite Element Analysis.
I. INTRODUCTION
A. Job History
Material handling could be a necessary and major factor of any productive activity. It's one thing which is common in each plant all
the time. Material handling is a technique that providing the correct quantity of material, within the perfect condition, at the proper
place, at the right time, within the right position and for the correct value, by victimization the correct methodology. It's merely
memorizing, moving, and lying down of materials through manufacture. It applies to the movement of raw materials, elements in
method, finished merchandise, packing materials, and disposal of scraps. In general, a lot and a thousand loads of materials are
handled daily requiring the utilization of enormous quantity of personnel whereas the movement of materials takes place from one
process space to a different or from one department to a different department of the plant contributes considerably to the overall cost
of producing. In the last many years material handling has become a replacement, complex, and speedily evolving science. For
moving material in and out of warehouse many varieties of kit and system are in use, counting on the kind of merchandise and
volume to be handled. The instrumentality is employed, in loading and unloading operations, for movement of products over short
distances. Existing platform used for material handling has additional self-mass; thus, it's poignant the mass carry capability. This
project aims to style and mass improvement of mass lifting platform.
Mass improvement are often achieved by victimization sandwiched structures rather than victimization flat plate as lifting platform.
To approaches exist to develop economic structures: either application of recent materials or the utilization of recent structural style.
A tried and well-established answer is that the use of composite materials and sandwich structures. During this approach high
strength to mass magnitude relation and minimum mass are typically obtained. The sandwich structures have potential to supply a
large vary of enticing style solutions. Additionally, to the obtained mass reduction, these solutions will usually bring house savings,
fireplace resistance, noise management and improved heating and cooling performance.
B. Significance
Hydraulic lifting platform is a versatile handling of machinery and equipment. Since the lift platform lift system is hydraulically
powered, so called hydraulic lifting platform. It is mainly used in mould manufacturing, chemical cans and containers, auto factories
and production lines, such as. Hydraulic lifting platform to meet the needs in the different height of the lifting, equipped with
various types of forms, using suitable control method, makes the lift is smooth and accurate, frequent starting, and a large capacity,
so that you can have small industrial enterprises to solve all kinds of problems when working to facilitate production. Hydraulic
lifting platform has many type, like four round mobile type lifting platform, and II round traction type lifting platform, and car
modified type lifting platform, and hand push type lifting platform, and hand type lifting platform, and make DC dual-use lifting
platform, and battery car type lifting platform, and cut fork itself type lifting platform, and car modified type lifting platform, and
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diesel engine song arm itself type lifting platform, and folding arm type lifting platform, and fixed type lifting platform, and sets
cylinder type lifting platform, and aluminium lifting platform and so on. Hydraulic lift platform manufacturers can also be
customized according to customer’s different needs in lifting height different specifications of the hydraulic lifting platform, safe
and convenient.
C. Strength Criteria
When the response of the panel is acknowledged, the structure is often checked against strength and maximum displacement criteria.
The strength criteria include overall buckling of the panel, local buckling of panel structural member’s faces and web plates and
their maximum tolerable local loads.
The behavior of steel sandwich panels under local impact loading will be investigated by means of laboratory testing, FE
simulations and analytical modelling. The Finite element analysis simulations follows the impact process and gives detail data about
the behavior of a panel throughout the impact. Based on this and the observation during the laboratory experiments, an analytical
model will be developed analyzing the deformation energy. The deformation energy, in case of the sandwich structure, can be
separated into three main components: bending and in plane load energy of the top plate and shear energy absorbed by the core
material. Deformation in shape and displacement can be then evaluated by equalizing the kinetic energy of the striking body with
the deformation energy of the panel.
II. LITERATURE REVIEW

Mr.Patil M.S Prof. Date D.D. and Prof. Ghalake A.B. in paper "MODIFICATION AND OPTIMIZATION IN STEEL SANDWICH
PANELS USING ANSYS WORKBENCH" The sandwich panel can be made of various types of core. The selection of core
dependent on type of application. The core like Z-core, Tube-core and Hat-core are easier to manufacture and provide good result
and also applicable for laser welding process. Special core such as V-core and I-core required specific manufacturing process, but
they are much lighter.
Narayan Pokharel and MahenMahendran in paper “Finite Element Analysis and Design of Sandwich Panels Subject to Local
Buckling Effects” Experimental analysis and finite element analysis is conducted to find out local buckling of top and bottom plate.
Also, appropriate model has been built to represent the result of local buckling of top and bottom plate which are supported by core
material of different core structure and experimental result has been compare with model analysis.
A.Gopichand,Dr.G.Krishnaiah, Mahesh Krishna ,Dr.Diwakar Reddy.V, .V.N.L.Sharma in paper “the structural analysis of
corrugated sandwich panel with chrome steel face sheets and low-carbon steel” This paper showed the simulation model of which
compressive strength has been compared with an experimental value and also on length basis strength to weight ratio is analysed.
W. Scott Burton, A.K. Noor in paper “Structural analysis of the adhesive bond in a honeycomb core sandwich panel sandwich
structures with honeycomb cores bond”
This paper showcased about sandwich panel with honeycomb structure which exist between top and bottom plate and structure has
been joined by means of adhesive. For proper functioning of joint flow ability of adhesive and properties of adhesive required for
heavy duty application.
Quanjin Ma,MRM Rejab1, JP Siregar and Zhongwei Guan in paper “A review of the recent trends on core structures and impact
response of sandwich panels”
This paper discussed on various type of core pattern and modes of impact failure. It is proving that core structure of sandwich panel
has a vital role in structural performance and application. There are three types of common loading on sandwich panel i.e.
compressive load, Impact load, and three-point bending and its application in aerospace, automotive, marine industries.
III. PROTOTYPE DESIGN

A. Introduction
Actual lifting plate having dimension 1200*1000*50 mm which is to be supported by the bracket .So manufacturing of such a big
lifting plate with bracket is very difficult task that’s why we decided to manufacture only small plate having dimension of
600*500*25 mm.
This plate act as a prototype of the actual plate and subjected the load of 500kg instead of load 1000kg.The load applied on plate is
proportional to the actual plate load ,So the results obtain from the Fusion 360 is used to compare with actual solid plate result
having same dimension as that of prototype.
1) Material Selection
Properties Aluminium Alloy (6061) Structural Steel (S275)

Density 2770 Kg/m3 7800 Kg/m3
Young’s Modulus 68.9 GPa 210 GPa
Poisson’s Ratio 0.18 0.3
Compressive yield strength 276 MPa 275 MPa
Tensile Ultimate Strength 310 MPa 370MPa
We have selected Aluminium Alloy (6061) over Structural Steel (S275) as aluminium alloy has a low density as compared to steel
but with comparative good amount of tensile ultimate strength and compressive yield strength. So, our main project objective gets
satisfied as a pellet should have a less weight but good amount of strength and weight carrying capacity.
B. Cores
We have selected different types of cores for analysis. The cores with dimensions are drawn with the help FUSION 360 2D drawing
and are listed below.
1) O-Core
Fig. 1. O-Core
2) Z-Core
Fig. 2. Z-Core
3) V-Core
Fig. 3. V-Core
4) C-Core
Fig. 4. C-Core
5) Honeycomb-Core
Fig. 5. Honeycomb-Core
6) Simple Solid Plate
Fig. 6. Simple Solid Plate
IV. FEM OF SANDWICH PANEL

A. Introduction
The finite element method (FEM) is a numerical methodology for finding issues of engineering and mathematical physics. Typical
issue region of interest consists of structural analysis, heat transfer, fluid flow, and electromagnetic potential. The analytical answer
of the issues typically needed the solution to boundary value problems for partial differential equations. The finite element method
formulation of the issue leads to a system of algebraic equations. The analysis yields approximate values of the unknowns at discrete
wide variety of factors over the domain. To resolve the issue, it subdivides an outsized problem into smaller and less complicated
parts that are referred as finite elements. The simple equations that model these finite elements are then assembled into a bigger
system of equations that models the whole problem. FEM then makes use of variation technique from the calculus of variations to
approximate an answer through minimizing an associated error function.
B. Basic Concept
The subdivision of an entire area into less complicated element has numerous advantages:
1) Accurate illustration of complicated geometry
2) Inclusion of different material properties
3) Easy illustration of the total solution
4) Capture of native effects.
A common work out of the approach involves (1) dividing the area of the problem into a set of subdomains, with every subdomain
represented by a group of element equations to the initial problem, followed by (2) systematically recombining all units of detail
equations into a global system of equations for the final computation.
The global system of equations has known solution techniques and might be calculated from the initial values of the initial problem
to get a numerical answer.
In the step one above, the element equations are simple equations that locally compare the original complex equations to be studied,
where the original equations are frequent partial differential equations (PDE). To explain the approximation on this method, FEM is
generally introduced as a special case of Galerkin method. The process, in mathematical language, is to construct an integral of the
inner product of the residual and the weight functions and set the integral to zero. In easy terms, it is a procedure that minimizes the
mistake of approximation by fitting trial functions into the PDE. The residual is the mistake because of the trial functions, and the
weight functions are polynomial approximation functions that project the residual. The method removes all the spatial derivatives
from the PDE, thus approximating the PDE locally with
a) A group of algebraic equations for steady state problems,
b) A group of ordinary differential equations for transient problems.
These equations are the element equations. They're linear if the underlying PDE is linear, and vice versa. Algebraic equation sets
that rise up with inside the state problems are answered using numerical linear algebra methods, while ordinary differential equation
sets that rise with inside the transient problems are answered by numerical integration using standard ways similar as Euler's system
or the Runge-Kutta system. In step (2) over, a global system of equations is generated from the element equations through a
coordinated transformation from the subdomains' local nodes to the domain's global nodes. This spatial transformation includes
adequate orientation adjustments applied related to the reference coordinate system. The process is often performed by FEM
software using coordinate data generated by the subdomains’ is best understood from its practical application, known as finite
element analysis (FEA). FEA as implemented in engineering is a computational device for performing engineering analysis. It
consists of the usage of mesh technology strategies for dividing a complicated problem into small factors, in addition to the usage of
software program application coded with FEM algorithm. In making use of FEA, the complicated problem is often a physical
system with the underlying physics which includes the Euler-Bernoulli beam equation, the heat equation, or the Naiver-Stokes
equations expressed in both PDE and necessary equations, at the same time as the divided small factors of the complicated problem
represent distinctive regions in the physical system.
FEA is a great choice for analysing issues over complex domains (like automobiles and oil pipelines), while the area changes (as
during a solid-country response with a shifting boundary), while the preferred precision varies over the complete area, or while the
answer lacks smoothness. For instance, in a frontal crash simulation it's far viable to increase prediction accuracy in "essential"
regions just like the front of the automobile and decrease it in its rear (as a consequence decreasing price of the simulation).
Another example would be in numerical weather prediction, wherever it's additional necessary to own correct predictions over
developing extremely nonlinear phenomena (such as tropical cyclones within the atmosphere, or eddies within the ocean) instead of
comparatively calm areas. So, we've used Fusion 360 software program for designing and Analysis. Following are the various
plates’ analysis.
C. Finite Element Analysis of Sandwich Pallet

1) C-Core
Fig. 7 Displacement Analysis of C- Core
Fig. 8 Stress Analysis of C-Core
2) Honeycomb Core
Fig. 9 Displacement Analysis of Honeycomb Core
Fig. 10 Stress Analysis of Honeycomb-Core
3) O-Core
Fig. 11 Displacement Analysis of O-Core
Fig. 12 Stress Analysis of O-Core
4) Z-Core
Fig. 13 Displacement Analysis of Z-Core
Fig. 14 Stress Analysis of Z-Core
5) V-Core
Fig. 15 Displacement Analysis of V-Core
Fig. 16 Stress Analysis of V-Core
6) Simple Solid Pallet
Fig. 17 Displacement Analysis of Simple Solid Pallet
Fig. 18 Stress Analysis of Simple Solid Pallet
V. RESULT AND CONCLUSION

A. Results
Type of Core Mass Maximum Stress Displacement(mm)

(In Kg) (In MPa)
1.C-Core 14.213 14.28 0.01992
2.Honeycomb 12.343 32.72 0.1137
3.O-Core 13.439 23.16 0.07822
4.Z-Core 14.606 28.85 0.05126
5.V-Core 12.667 69.05 0.1341
6.Simple Solid Plate 20.288 30.42 0.09013
B. Conclusion
After performing several non-destructive finite element analysis on fusion 360, we have come to conclusion that C-core has a less
amount of stress as well as a minimum deformation and also has an optimum weight than other core and conventional solid plate.
REFERENCE
[1] Mr.Patil M.S Prof. Date D.D. And Prof. Ghalake A.B. In Paper "Modification And Optimization In Steel Sandwich Panels Using Ansys Workbench"
[2] The mechanical behavior of corrugated-core sandwich panels M.R.M. Rejab a,b, W.J. Cantwell ca School of Engineering, University of Liverpool, Brownlow
Hill, Liverpool L69 3GH, United Kingdom-2012
[3] Evaluation of Stiffness Terms for Z-cored Sandwich Panels D. Zangani & M. Robinson & A. G. Gibson Published: 11 Sept 2007
[4] Impact response of aluminum corrugated core sandwich panel H.N.G. Wadley*, K.P. Dharmasena, M.R. O’Masta, J.J.Wetzel-2013.
[5] Homogenization of corrugated core sandwich panel Natacha Buannic a, Patrice Cartraud b,Tanguy Quesnel Principia Marine,1 Rue de la Noee, B.P. 72108,
44321 Nantes Cedex 3, France
[6] Numerical simulation of bending and failure behaviour of z-core sandwich panel D. Zangani, M. Robinson, A. G. Gibson, L. Torre and J. A. Holmberg-
November-2007
[7] Study on Sandwich Core Modeling for Structural Analysis of Sandwich Composite Structure Hyunbum Park1,a1Department of Defense Science & Technology
- Aeronautics, Howon University 54058, 64 Howondae 3gil, Impi, Gunsan, Rep. of Korea-2018
[8] Narayan Pokharel and MahenMahendran in paper “Finite Element Analysis and Design of Sandwich Panels Subject to Local Buckling Effects

Design and Analysis of Weight Lifting Pallet With Respect To Sandwich Pattern of Pallet

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10 I January 2022

Design and Analysis of Weight Lifting Pallet with

II. LITERATURE REVIEW

III. PROTOTYPE DESIGN

Properties Aluminium Alloy (6061) Structural Steel (S275)

6) Simple Solid Plate

Fig. 6. Simple Solid Plate

IV. FEM OF SANDWICH PANEL

C. Finite Element Analysis of Sandwich Pallet

Fig. 7 Displacement Analysis of C- Core

Fig. 8 Stress Analysis of C-Core

Fig. 9 Displacement Analysis of Honeycomb Core

Fig. 10 Stress Analysis of Honeycomb-Core

Fig. 11 Displacement Analysis of O-Core

Fig. 12 Stress Analysis of O-Core

Fig. 13 Displacement Analysis of Z-Core

Fig. 14 Stress Analysis of Z-Core

Fig. 15 Displacement Analysis of V-Core

Fig. 16 Stress Analysis of V-Core

6) Simple Solid Pallet

Fig. 17 Displacement Analysis of Simple Solid Pallet

Fig. 18 Stress Analysis of Simple Solid Pallet

V. RESULT AND CONCLUSION

Type of Core Mass Maximum Stress Displacement(mm)

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