This document presents a case study report on the finite element stress analysis of an undercarriage structure for a stacker-reclaimer machine with a capacity of 1800 tons/hour for stacking and 2000 tons/hour for reclaiming. The study uses finite element modeling to simulate and analyze the stresses on the gantry and traveling system, which experience the most stress. The maximum stresses are compared to permissible standards to evaluate the structural behavior under critical loading conditions and identify critical areas. The document describes the geometry, boundary conditions, numerical approach using ANSYS, standards, and results of the analysis.

1. Finite element stress analysis of a stacker-
reclaimer machine: A case study report
(undercarriage structure)
For Goharzamin Iron Ore Company
April 2021

2. “
2
Authors
Erfan Khodabandeh, Shahaboddin Amini , Aliakbar Taghipour
Central Technical Office, Goharzamin Iron Ore Company
Mine and Plants: 50th Km of Shiraz Road, Sirjan, Iran
Central Office: Western Arash 12, Africa Blvd., Tehran Iran
Corresponding author: Erfan Khodabandeh
Email: E.khodabandeh@aut.ac.ir
Khodabandeh.e.1989@gmail.com

3. 3
Contents
Introduction
Geometry
Boundary Conditions
Numerical Approach
Standards
Results

4. 1. Introduction

5. 5
Handling of bulk materials play an important role in the modern economy. In
recent years the volume of handled bulk materials has been steadily increased. In
order to make long-distance transportation more economical, various types of
bulk handling equipment and trans-shipping procedures have been developed.
The handling of raw bulk materials constitutes a significant cost portion of the
final product. Numerous systems of this kind are installed at mineral processing
and coal power plants where large stockpiles of ore or coal need to be handled.

6. 6
In this report, the calculations and structural design of a Stacker-Reclaimer
machine at Goharzamin Iron Ore Company with capacity of 1800 ton/h in
stacking and 2000 ton/h in reclaiming, has been audited. Relying on numerical
modeling knowledge (FEM), the two parts of the stacker-reclaimer machine
(gantry and traveling system), which withstand the most stress, are simulated.
The main goal of this study is to investigate the behavior of these parts under
critical loading condition, also identify the critical area. The maximum stresses in
different parts of the considered structure are compared with permissible values.

7. 7

8. 2. Geometry

9. 9
1 Traveling system 6 Tension links
2 Gantry 7 A-frame
3 Slewing platform 8 Counter weight boom
4 Main boom 9 Counter weight
5 Bucket wheel 10 Tension links
Items Quantity
Capacity in reclaiming (ton/h) 2000
Capacity in stacking (ton/h) 1800
Height (m) 25
Length (including tripper car) (m) 110
Width (m) 12
Working slewing angle (degree) -110 to 110
Working luffing angle (degree) -9 to 9
Main boom (m) 45
Bucket capacity (lit) 525
Buckets 8

10. 3. Boundary Conditions

11. 11
In this simulation, for support condition, the real allowable movements of the
wheels on the rail are released (Figure 3). For this purpose, one wheel has been
fixed in all directions (highlighted in red frame). The other wheels have been
limited in such a way that the structure is allowed to move on the rail. The applied
limitation is shown in figure 3. Moreover, for the connection of parts which are
shown in figure 4, revolute-joints are utilized. A revolute joint is a one-degree-of-
freedom kinematic pair used frequently in mechanisms and machines. The joint
constrains the motion of two bodies to the pure rotation along a common axis. The
joint does not allow translation or sliding linear motion. Also, other connection of
solid material is bonded. For simplification, in this study, the wheels and shafts are
removed and the supporting plates including the hole surfaces are fixed as
boundary condition

12. 12
(a) (d)
(b) (c)
Figure 2. 3D model of considered geometry (a) main body (b) gantry (c) traveling system (d) built equipment

13. 13
Figure 3. The boundary condition used in this study: Red frame: Fix, Blue frame: Dy: Free and Dx, Dz: Fix,
Yellow frame: Dy & Dx: Free, Dz:Fix
Figure 4. The revolute joints used in this study are highlighted in red frame

14. 4. Numerical approach

15. 15
In order to predict the stress distribution of structure under different forces loading, the considered geometry
has been modeled with FEM package ANSYS. ANSYS-Workbench is an interactive environment for
simulation and solving all kinds of engineering and scientific problems based on partial differential
equations (PDE). This software uses the proven finite element method (FEM).

16. Meshing
16
Figure 5. The grid type used in this study
Due to accuracy of solid elements in comparison with shells and beams, a 3D mesh of the structure with
approximately 120,000 2nd order elements is created. All the welded plated and member are merged together
for simplicity. Please note that solid modeling with 3D elements provides not only higher accuracy but also it
yields ease of geometrical modeling and meshing because the original 3D model can be directly employed and
it can be easily meshed with tetrahedral elements.

17. Loading
17
In this study, the most critical state, including reclaiming
working, 45 degrees for slewing angle, and 9 degrees for
luffing angle, have been considered. In this condition, the
forces are as follows:
Fz:-374.8 ton, Fx & Fz:0 ton, Mx:516.2 ton.m, My:-524.1
ton.m, Mz:0 ton.m

18. 18

19. 5. Standards

20. 20

21. 6. Results

22. 22

23. 23

24. 24

25. 25

26. Acknowledgement
The authors would like to express their
special thanks for the provided supports
and funding resources by Goharzamin
Iron Ore Company and the technical
office department.
26

27. Maps
our office
27
Findmoremapsat https://goo.gl/maps/YUDA2rU4yagfuFa16