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MEG DESIGN
DRIVEN BY
VALUES,
DELIVERING
OF A VISION, PRODUCES IRON, SOFT IRON, CAST IRON,
DETERMINED
TO INNOVATE ALLOY, LOCOMOTIVE PARTS, AGRICULURAL
EQUIPMENT, MACHINERY, TINPLATE, CABLE
AND WIRE, AND REBARS
EMBRACING
RENEWABLE
RESOURCES IN FY17 TATA STEEL HAD A GLOBAL
OF ENERGY
FOR ENSURING
ANNUAL CRUDE STEEL DELIVERIES
SUSTAINABLE OF 27.5 MILLION TONNES
FUTURE
CUSTOMER’S EXPECTATIONS OF RELIABILITY ARE MET FULLY
DESIGN FOR
THROUGHOUT THE LIFE OF THE PRODUCTS WITH LOW OVERALL
RELIABILITY LIFE CYCLE COSTS
DESIGN FOR DESIGNS ARE MODIFIED TO FIT THE WORKER, NOT THE OTHER WAY
SAFETY AND ROUND. ELIMINATE DISCOMFORT AND RISK OF INJURY DUE TO
ERGONOMICS WORK
PORTFOLIO
DESIGN
QUICK
SKILLED WORKERS AND ADVANCED TECHNOLOGY FACILITATES
RESTORATION IMMEDIATE RESTORATION IN CASE OF EQUIPMENT FAILURE
OF EQUIPMENT
CAST HOUSE
FLOOR
PROBLEM STATEMENT
DESCRIPTION:
CURRENTLY, THE MAINTENANCE PROCEDURE FOR THE TILTING RUNNER IS CARRIED OUT IN THE
CAST HOUSE FLOOR ITSELF. The critical concerns are:
SAFETY ISSUES FOR THE OPERATORS
MAINTENANCE WORK IS IN SERIES WITH OTHER CAST HOUSE OPERATIONS
AFFECTS THE AVAILABILITY AND RELIABILITY OF CRANE
GOAL STATEMENT:
TO SUGGEST A SUITABLE ARRANGEMENT BY WHICH THE MAINTENANCE WORK CAN BE
PERFORMED AT AN ANOTHER SUITABLE SERVICE AREA RATHER THAN IN THE CAST HOUSE FLOOR.
TROUGH
TILTING
RUNNER
DESCRIPTION
•Cast house equipment
•Short and precisely fabricated iron
runners, reduced refractory and
maintenance cost
•Body material- Mild steel
•Lining material- Refractory
•Weight - 30tonnes
•Drive system- Pneumatic drive with
tie rod arrangement
•Rugged designs
WORKING
•Position - Between two hot metal
tracks for reliable and safe teeming
of hot metal cast
•Operation - First tilted to fill the hot
metal ladle on one track and then
tilted back to fill the ladle on the
other track
BENEFITS OF REFRACTORY
HOT METAL
TILTING RUNNER CAST HOUSE LINING:
LADLE
IN OPERATION FLOOR •Insulation to withstand high
temperatures
•Protect the tilting runner from
thermal shocks, abrasion and
chemical attack
CRACKING AND
DIFFERENTIAL
PEELING OFF OF
THERMAL
REFRACTORY
EXPANSION
LINING DUE TO
OF METAL AND
HEATING AND
RFRACTORY
COOLING CYCLES
DEPOSITION OF
ABRASIVE WEAR
HOT METAL
OXIDATION AND
THERMAL FATIGUE
ALKALI ATTACK
A TILTING
RUNNER KEPT
HIGH SURFACE ON THE CAST
CAST HOUSE
OPERATING HOUSE FLOOR
TEMPERATURES FLOOR
FOR
PERFORMING
MAINTENANCE
WORK
DRAWBACKS OF CURRENT MAINTENANCE METHOD
MAN-MACHINE INTERFACE
FOR DOING THIS, WE NEED A TILTING RUNNER HANDLING ARRANGEMENT THAT CAN MOUNT
THE TILTING RUNNER AND THIS ASSEMBLY CAN BE CARRIED TO THE MAINTENANCE SITE
WITH THE HELP OF A TRAILER.
REDUCTION OF MAN-
MACHINE INTERFACE AT
CAST HOUSE FLOOR
SAFETY
IMPROVEMENT IN CRANE
AVAILIBILTY AVAILIBILITY AT CAST
HOUSE
MODEL DEVELOPMENT STAGES
1 2
The structure
clamped to the Four beams
trailer bed incorporated to fix
the structure onto
the floor
3 4
Support beams
Hydraulic jack incorporated to fix
and hand pump the structure onto
arrangement was the floor by screw
made nut mechanism
DESIGN CONSIDERATIONS
CONCEPT DEVELOPMENT 1.
2.
Selection of materials
Easy to install and dismantle
3. High strength to weight ratio
4. Shape, size, flexibility and maintenance
5. Load carrying members should have higher section modulus
STAGE 1: 6. Weight and cost
7. Thermal, manufacturing, environmental and aesthetics
A STRUCTURE TO MOUNT THE TILTING RUNNER SUPPORTING
LOAD CARRYING MEMBERS MEMBERS
FRAME DEVELOPMENT
FIXED TO GROUND
FOR HYDRAULIC JACK
TILTING RUNNER MOUNTED ON THE STRUCTURE FIXED TO TRAILER
BED
TILTING
FV TV
RUNNER
TRAILER
LOAD
CARRYING
MEMBERS
FIXED TO
FLOOR
FRAME
FIXED TO FOR HYDRAULIC TILTING
TRAILER BED JACK RUNNER
Continued..
SECTION DEVELOPMENT
Here, Z is the section modulus
1. FOR LOAD CARRYING MEMBERS:
B
ℍ
h
H
b/2
I -SECTION
BOX SECTION
H
h
b
Continued..
I-SECTION, Since they should have high strength but weight of the structure should be kept minimum
Continued..
STAGE 2:
A CARRIAGE TO CARRY THE TILTING RUNNER MOUNTED ON THE STRUCTURE TO THE
MAINTENANCE SITE
SELECTION CRITERIA
1. Complexity of the site FV
TILTING
2. Lower centre of gravity
3. Effect of gravity, weight and centrifugal forces RUNNER
4. Optimum Velocity and turning radius
STRUCTURE
FRAME
1300
LOAD CARRYING
MEMBER (2 IN NO’s) .
SITTING POSITION OF
TILTING RUNNER SUPPORT BEAMS FOR
TILTING RUNNER TO
PREVENT LINEAR OR
SUPPORT BEAMS ANGULAR MOTION
FOR
STRENGTHENING
THE STRUCTURE
CLAMPING SCREW
NUT ARRANGEMENT
(4 in NO’s) CLAMPING
MECHANISM VIA
SCREW NUT WEIGHT OF EQUIPMENT =
5TON
POSITION OF HYDRAULIC JACK WEIGHT OF TILTING
(4 in NO’s). LIFTING OR RUNNER = 30TON
LOWERING MECHANISM TOTAL WEIGHT = 35TON
ALONG WITH HAND PUMP BASE PLATE
RESTING ON THE
STOOL
LOAD CARRYING MEMBER FOR
PLATFORM FOR THE ASSEMBLY WHEN PLACED
HAND PUMP ON THE FLOOR DURING
SERVICING(4 in NO’s). SUPPORT
MECHANISM VIA SCREW NUT
Continued..
FRONT VIEW
TOP VIEW
Areas of application of
point load
CASE3:
Fixed to the floor
during maintenance
period (at all 4
positions)
CASE2:
Fixed on a stool and the
assembly is lifted by For structural steel :
application of pressure
(at all four positions) YIELD STRESS = 250 Mpa (min)
ULTIMATE TENSILE STRESS = 400-550 MPa
EQUIVALENT STRESS
CASE 1: When the structure is clamped to the CASE 2: When the tilting runner is lifted or
trailer bed lowered using hydraulic jack and hand pump
CONCLUSION: CONCLUSION:
The stress acting on the load carrying members is within the permissible The stress acting on the load carrying members is within the
value permissible value
⇒ OVERALL STRESS < 100MPa (much less than the yielding value) ⇒ OVERALL STRESS < 100MPa (much less than the yielding value)
Thus the design is safe under this condition of load and support! FOS = 2.8 Thus the design is safe under this condition of load and support! FOS = 5
CONCLUSION:
The stress acting on the load carrying members
is within the permissible value
⇒ (OVERALL STRESS < 100MPa
NO RED ZONE ON THE LOAD much less than the yielding value)
CARRYING MEMBERS Thus the design is safe under this condition of
load and support! FOS = 4
TOTAL DEFORMATION
CASE 1: When the structure is clamped to the CASE 2: When the tilting runner is lifted or
trailer bed lowered using hydraulic jack and hand pump
CONCLUSION:
CONCLUSION:
THRESHOLD LIMIT = Length/100 = 3570/100 = 35.7mm
THRESHOLD LIMIT = Length/100 = 3570/100 = 35.7mm
Since, Maximum deflection =1.3456mm << threshold limit
Since, Maximum deflection = 2.4804mm << threshold limit
⇒DESIGN IS SAFE! ⇒DESIGN IS SAFE!
CONCLUSION:
THRESHOLD LIMIT = Length/100 = 3570/100 =
LOAD CARRYING MEMBERS
35.7mm
LENGTH = 3570mm Since, Maximum deflection =2.7mm << threshold limit
⇒DESIGN IS SAFE!
REVIEW OF ANSYS EVALUATION
STRESS ON LOAD
CARRYING 90MPa 50MPa 60MPa
MEMBERS
FOS 2.8 5 4
MAXIMUM
DEFORMATION 2.48mm 1.3456mm 2.7mm
COMMENTS:
For all the three cases stress on the load carrying members is within the limiting value of yield stress for structural
steel i.e 250MPa. Thus design is safe!
The FOS is higher when the structure is fixed to floor i.e. during maintenance than that when clamped to the trailer
⇒The structure is safe from design point of view.
The maximum deflection is highest when the fixed point are farthest from the load carrying members. But in all
three cases it is much less than its threshold value. Thus design is safe!
Total weight ‘W’ = Weight of tilting runner ‘Wt’ +
Weight of equipment ‘We’
=> (30000+5000)*9.8 = 343000 N
Frictional force F = (Friction coeff.) *W
=> 0.16*343000 = 54880 N
This frictional force ‘F ‘ is the limiting value for
clamping force i.e. Clamping force ‘Fc’ should be
greater than or equal to ‘F’ in order to avoid
LOCATION IN THE
coupling.. STRUCTURE
Taking Clamping force on one screw nut as Fc:-
Let Fc = F = 54880 N
Let d = bolt diameter = 30mm
Let k = nut factor = 0.17
Let T = bolt torque = Fc*K*d
=> T = 54880*0.17*30
= 2.79888*10^5
CLAMPING
POSITION
Trapezoidal Thread used is TR 30*6
Thread specifications: d = nominal diameter = 30mm
P = pitch = 6mm
d3 = root diameter = 27mm
d2 = pitch diameter = 24mm
As= effective stress area of thread
=> {(22/7)*(d3 + d2)^2}/16
= 510.705 sq.mm
Bolt used is 4.6 GRADE BOLT
Bolt specifications : proof stress = 225 Mpa
yield stress = 240 Mpa (min)
tensile stress = 400 Mpa (min)
From above calculations:
Minimum stress developed in the screw nut = Fc/As
= 107.456MPa
Since the stress developed is less than the
limiting value for 4.6 grade bolt, design is safe!
We are using a 8.8 GRADE BOLT for this operation to have
higher clamping force; Its specifications are:
Tensile stress = 800MPa
Yield stress = 640MPa
When the tilting runner and structure are mounted on the trailer, and the trailer moves around a horizontal
circular path, centripetal force is provided by frictional force between trailer and the assembly
Thus the maximum centrifugal force ‘Fcg’ that can act on the system is same as friction ‘F’.
NOMENCLATURE:
M = mass of tilting runner + mass of equipment = 35000Kg
R = Turning radius in m
µ = Friction coefficient = 0.16
V = velocity of trailer in Km/hr
g = acceleration due to gravity= 9.8m/s²
F = 0.16*35000*9.8 = 54880 N
Fcg = (M* V²)/R
Condition for Safe loading
Fcg ≤ F
TRAILER BED
TO FIND OPTIMUM RANGE OF SPEED AND TURNING RADIUS
Comparison between velocity and turning radius:-
V
Velocity V Turning radius R Centrifugal force Fcg
(in km/hr) (in m) (in N) [Fcg ≤54880N]
10 20 13503.10
10 10 27006.20
10 5 54012.30
15 20 30381.90
15 15 40509.30 R
15 12 50636.60
15 11 55236.60 RECOMMENDATION-
OPTIMUM SPEED RANGE =
10km/hr – 15 km/hr
OPTIMUM TURNING RADIUS =
At V = 15 km/hr and R = 11m , Fc > F, which ≥12m
doesn’t satisfy the condition
Thus we conclude:
For V ≤ 15km/hr, R should be ≥11.5m
HYDRAULIC CYLINDER
SPECIFICATIONS HAND PUMP
Cylinder capacity = 30ton
SPECIFICATIONS
Type= double acting
Stroke length = 368mm Type - double acting
No. of cylinders required = 4 Oil output per stroke = 5.7
Total Load on all 4 cylinders = cc
35ton Handle force = 50.8Kg
Cylinder diameter= 85mm
Required lift = 100mm
LOCATION IN THE
STRUCTURE
Let R = radius of cylinder = 42.5mm PRINCIPLE OF HYDRAULIC JACK
Let H = required lift = 100mm
Volume of hydraulic cylinder V = Π*R²*H
⇒V = 5.67*10² cc
Net volume of 4 cylinders V’ = 2.2698*10³ cc
Pump output per stroke Po = 5.7 cc