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Analysis of Excavator Bucket. using Ansys.

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 IJSRD - International Journal for Scientific Research & Development| Vol. 8, Issue 5, 2020 | ISSN (online): 2321-0613

Analysis of Excavator Bucket Using Ansys

Shaik Meeravali1 Dr. M. Sri Rama Murthy2
1,2
SIR C R Reddy College of Engineering, Eluru, India
Abstract— Generally excavator buckets are made with solid
B. Bucket Digging Force:
steel. The analysis of excavator bucket lugs is carried over
two steel alloy materials such 1.SM50A, 2.SCNCr2B. The Bucket digging force is defined as maximum digging force
main objective of this project is to select the metal which is due to bucket cylinder in tangential direction at bucket
suitable for the maximum life of the excavator bucket. The tooth.
earth moving machine industries are rapidly growing as 1) Pressure of Bucket Cylinder:
rapid growth in construction work confident through the day It is the pressure of bucket cylinder according to the
by day increased performance of construction machines. operation pressure of hydraulic oil, it is depend on the next
This paper gives focuses on the evaluation method of formulation:
digging forces required to dig the terrene for light and heavy F2= (�/4)* Db 2 * Pb
duty construction work, as well as society infrastructure Bucket digging force:
developing work. This process deals the force calculation Fb = (F2∗ A∗ C)/ (R1∗ B)
for required part in the excavator machine to calculate the Values Found by Actual Practical Observation:
life of particular part-excavator bucket and its failure. In A= 620mm
progress the design of bucket with suitable material to give B= 820mm
good fatigue condition as well as good life of particular part C= 490mm
of excavator bucket lug. R1= 1325mm
Keywords: Digging, Trenching, Fatigue, Design Db= 125mm
Optimization, Ansys14.5 Pb= 0.071Mpa
2) Calculations:
I. INTRODUCTION F2= (�/4)* Db 2 * Pb =(.785)*15625*0.071 = 870.85KN
Fb = (F2∗ A∗ C)/ (R1∗ B) =(870.85*620*490)/(1325*820)
In highway construction, in trenches digging, for mining,
=243.501KN
and for heavy soil removal purpose. The digging machines
3) Arm Digging Force:
are also called backhoe loaders and backhoe excavators. For
Arm digging force is defined as maximum digging force due
dig the earth the hydraulic excavators are used, like these
to arm cylinder in tangential direction at bucket tooth in
applications & to load the any material into the goods
position where bucket tooth force due to bucket cylinder is
trucks. The digging machines are used mainly to lift below
maximized.
the surface of the ground on which the machine rests.
4) Pressure of arm cylinder:
According to Forestry applications, these excavator
It is the pressure of arm cylinder according to the working
machines are self-propelled wheeled machines. These
pressure of hydraulic oil, and it is depend on the next
machines are working on the road and off the road. These
formulation:
machines are set to see loader arms at one end & that is for
supporting a full width bucket attachment, the other end is C. Arm digging force:
supporting with boom and arm combination with capable of 1) Force Explanation:
rotates it-self half circle for the purpose of trenching and
other digging operations. The excavator machine is also
used as a utility machine at heavy construction sites like
construction of heavy bridges & constructions of railway
track and some kind of infrastructure projects, these
hydraulic machines are operated by skilled persons, while
the machine is operated the safety precautions should be
fallow otherwise the impact of the hydraulic machine
accidents are very dangerous effect to human being.

II. CALCULATION OF DIGGING FORCES OF BUCKET AND ARM

A. Forces

F1= (�/4) Da2 *

Pa Fa = F1∗ R3
R2

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 Analysis of Excavator Bucket Using Ansys
(IJSRD/Vol. 8/Issue 5/2020/046)

Values Found by Actual Practical Observation: D. 3D model of Bucket

R2= 3750mm
R3= 640mm
Da= 135mm, Pa= 0.061Mpa
F1= (�/4) Da2 * Pa
F1= (0.785) *18225*0.061
F1=872.70KN
Fa = F1∗ R3 R2 = 701.38∗ 650 3700 = 123.21kN
Arm digging force = 123.21kN

III. MATERIAL PROPERTIES REQUIRED FOR ANALYSIS:

A. SM50A:
It contains proportion of materials as C=0.22%, Si=0.55%,
Mn=1.6%, P=0.035%, S=0.035%
Properties of material
Young's Modulus: 2*10 5 MPa
Tensile Strength: 800MPa
Yield Strength: 450MPa
IV. ANALYSIS RESULTS FOR BUCKET FOR DYNAMIC
Elongation: 8-25%
LOADING
Density : 7700kr/m3
A. Boundary Conditions and force application-
B. SCNCrM2B:
It contains proportion of materials as C=0.25-.35%,
Si=0.08%,
Mn=1%,Ni=2% ,Mo=0.15-.35%,Cr=.03-.09%
Properties of material
Young's Modulus: 2*10 5 MPa
Tensile Strength: 880MPa
Yield Strength: 645MPa
Elongation: 9%
Density : 7700 kg/m3
B. Mesh view of bucket-
C. 2D modeling of buckect-

C. Max stress view at lugs of bucket SM50A material

Bucket-

By taking all measurements in mm the 2d bucket

figure is draw in auto cad 2012 software

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 Analysis of Excavator Bucket Using Ansys
(IJSRD/Vol. 8/Issue 5/2020/046)

Result Existing bucket material SM50A D. Optimized bucket model

Total deformation 2.76mm
Max stress 510MPa
1) 1st analysis carried with steel alloy SM50A &
calculation:
By using Goodman's Fatigue life calculation method
prediction of fatigue life as:
Mean Stress(X) = (�max+�min)/ 2 = (511.06+37.54) /2 =
274.30MPa
Alternating Stress(Y) = (�max−�min)/ 2 =
(511.06−37.54)
/2 = 236.76MPa
Now,
Slope (m) = �alternate/ ����� = 236.76/ 274.30 = 0.86
Coordinate (Y1) = (Endurance limit- mX) =400-
(0.86*274.30) = 164.10MPa
Margin of Safety = Y1/ Y =164.10 /236.76 = 0.693 E. Mesh View of Optimized Bucket-
Margin of Safety < 1 so that design is not safe
By using above calculated results and material properties we
can calculate the fatigue Life in e-fatigue calculation =
449260cycles = 124.79hrs
a) Graphical view for SM50A material result:

F. Max stress view at lugs of SCNCrM2B material Bucket-

2) 2nd design and analsys of bucket and lugs –here analysis

carried out with steel allaoy SCNCrM2B-
After the first basic design and analysis the calculations and
results, we observe the life of the bucket is minimum and
which is below 150hrs.This gives the bucket is non-suited
for long operations purpose, with considering present Result bucket material SCNCrM2B
situation in construction operations around world there is Total deformation 2.41mm
serious need of re-design & optimization of bucket to give Max stress 510MPa
life span above minimum 1000hrs. Redesign & optimization 1) 2nd analysis carried with steel alloy SCNCrM2B &
is the operation in which we are going to point out the calculation:
places where is the failure is spotted during stress coming on By using Goodman's Fatigue life calculation method
it and redesign those places in good condition way which prediction of fatigue life as:
will give us maximum better results. By considering the Mean Stress(X) = (�max+�min)/ 2 = (315.83+43.3)/ 2 =
previous all results, we saw and observing in analysis figure, 179.56MPa
the maximum stress is found at lugs of the bucket and we Alternating Stress(Y) = (�max−�min)/ 2 = (315.83−43.3)/
consider that is the reason of failure of the bucket. Hence 2nd 2
material SCNCrM2B is considered and analysis done for = 136.26MPa
better design results. The following are the results with the Now,
new material. Slope (m) = �alternate/ ����� = 157.89/ 157.93 = 0.07
Coordinate (Y1) = (Endurance limit- mX)=450-
(0.07*179.56) = 437.43MPa
Margin of Safety = Y1 /Y =437.43/136.26 = 3.20
Margin of Safety > 1 so that design is safe

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 Analysis of Excavator Bucket Using Ansys
(IJSRD/Vol. 8/Issue 5/2020/046)

By using above calculated results and material A. Overall graph for two material result:
properties we can calculate the fatigue Life in e-fatigue
application in internet = 4623655cycles
= 980hrs
2) Graphical view for material SCNCrM2B result:

VI. CONCLUSION
The analysis is done with two steel alloy materials and
fatigue life is calculated for both, it is found that the fatigue
life for SM50A and SCNCrM2B materials are 124hrs &
3) Tabular form for fatigue life calculation 980hrs respectively. Comparing two materials, SCNCrM2B
Fatigue life cycle calculating values is best suitable for excavator bucket.
For SM50A material For SCNCrM2B material
Max 511.06Mp Max 315.83Mp REFERENCES
stress(�max) a stress(�max) a [1] Andrew Hall (2002), “Characterizing the Operation of a
Min Min Large Hydraulic Excavator”, p. 1, Thesis of Master of
stress(�min) 37.54Mpa stress(�min) 43.3Mpa
Philosophy, School of Engineering, The University of
Mean 274.30Mp Mean 179.56Mp Queensland Brisbane, Australia.
stress(X) a stress(X) a [2] Bhaveshkumar P Patel and Prajapati J M (2011a), “A
Alternate 236.76Mp Alternate 136.26Mp Review on FEA and Optimization of Backhoe
stress(Y) a stress(Y) a Attachment in Hydraulic Excavator”, IACSIT,
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Coordinate(Y1 Coordinate(Y1 436.17Mp Vol. 3, No. 5, pp. 505-511.
164.10
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[5] Mehmet Yener (2005), “Design of a Computer Interface
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