Fatigue life prediction of heavy mining equipment. Part 1: Fatigue load assessment and crack growth rate tests

Yin, Yue; Grondin, Gilbert Y.; Obaia, Khaled; Elwi, Alaa E.

doi:10.1016/j.jcsr.2007.01.008

Cited by 25 publications

(10 citation statements)

References 6 publications

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“…Using this cycle time and assuming a 95% shovel operational efficiency, the total number of digging cycles for shovel is calculated as 2730 cycles per day. This assumption is very close to field observations [22] where researchers counted 2880 cycles per day for a cable shovel working continuously over a period of 2 weeks. For this research, a middle-ground value of 2800 cycles per day is assumed to convert the cycles to days.…”

Section: Remaining Life Expectancy Of Dipper Componentssupporting

confidence: 80%

“…One research reported csag40.21-350WT steel used for shovel boom [21]. This steel has high yield strength of 320 MPa [21,22]. It is assumed in this study that the same steel is used for the dipper and the shovel boom, and their properties are given in Table 4.…”

Section: Shovel Stress Modeling and Analysismentioning

confidence: 99%

“…The "c" values are between 3 and 4, and some common values for "m" are available in literature [33]. For this research, the material constants are taken from research conducted by Yin et al [21,22]. They estimated the crack growth for the shovel boom cracks and measured the material constants ("c" and "m") following the ASTM standard E1820:…”

Section: Remaining Life Expectancy Of Dipper Componentsmentioning

confidence: 99%

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Mechanics of Electric Rope Shovel Performance and Reliability in Formation Excavation

Raza¹,

Frimpong²

2017

Lagrangian Mechanics

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Large-capacity rope shovels are used as primary production equipment in many surface mining operations. Current rope shovels have payload capacities in excess of 100 tons per pass. The dynamic payload and formation resistive forces result in severe stress loading of the shovel front-end assembly. Material flaws, high stresses, and harsh excavation conditions can initiate cracks in the dipper-teeth assembly. These cracks, under high stresses, can propagate to critical lengths resulting in fatigue failure of frontend assembly. Dipper-related problems can significantly reduce shovel availability. There is no fundamental research for understanding dipper fatigue failure resulting from high stress intensity, crack initiation, and propagation, the subject matter of this study. The Newton-Euler algorithm is used to build kinematics and dynamic models of the cable shovel front-end assembly. The models incorporate the dynamic resistive forces on the dipper-teeth assembly. Numerical simulations are used to generate the dynamic payload force and its dynamic left. Virtual simulation, based on the P&H 4100XPC shovel prototype in ANSYS (R15), is run to generate stress loading of the dipper-teeth assembly and equivalent (von Mises) stresses. Stress intensity factors are computed for various crack lengths in the dipper-teeth assembly, and the crackpropagation lives are computed for these cracks. The results show that a 75-mm crack can propagate to the critical length in 16 days. This research study provides a pioneering effort toward understanding shovel dipper fatigue failure due to high stress intensity, crack initiation, and propagation for understanding shovel reliability and availability for production efficiency and bulk production economics.

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Section: Remaining Life Expectancy Of Dipper Componentssupporting

confidence: 80%

Section: Shovel Stress Modeling and Analysismentioning

confidence: 99%

Section: Remaining Life Expectancy Of Dipper Componentsmentioning

confidence: 99%

See 1 more Smart Citation

Mechanics of Electric Rope Shovel Performance and Reliability in Formation Excavation

Raza¹,

Frimpong²

2017

Lagrangian Mechanics

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“…The only reported work is done by [56][57][58] who estimated the fatigue life for corner cracks in the steel welded box section of the shovel boom. The researchers used finite element method to estimate the crack growth rate, and metal properties were found in the lab using standard procedures.…”

Section: Ultimate Failurementioning

confidence: 99%

Cable Shovel Stress & Fatigue Failure Modeling - Causes and Solution Strategies Review

Raza

Frimpong²

2013

J Powder Metall Min

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“…BWEs operate in very harsh conditions, being exposed to extreme dynamic and stochastic loads. Improvements have been made in the estimation of working loads (Czmochowski, 2008;Bošnjak et al, 2009b;Gottvald and Kala, 2012), calculation methods (Bošnjak et al, 2006;Gottvald, 2010;Rusiński et al, 2010b;, production technologies and monitoring of vital subsystems (Bartelmus, 2006;Rişteiu et al, 2006;Yin et al, 2007;2008;Bartelmus and Zimorz, 2009). However, failures of structural elements (Bošnjak et al, 2009a;Rusiński et al, 2010a; and mechanisms (Dudek et al, 2011;Savković et al, 2011) are almost inevitable during BWE operation.…”

Section: Introductionmentioning

confidence: 99%

Basic parameters of the static stability, loads and strength of the vital parts of a bucket wheel excavator’s slewing superstructure

Bošnjak

Gnjatović

Savićević

et al. 2016

J. Zhejiang Univ. Sci. A

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Determining a bucket wheel excavator (BWE)'s slewing superstructure weight and its center of gravity (COG) is of extreme importance not only in the design phase, but also after the completion of the erection process and during the operation of the machine. This paper presents a critical comparative analysis of the basic parameters of the static stability of a BWE 1600 superstructure, with the parameters being obtained by both analytical and experimental procedures. The analysis shows that a relatively small difference in superstructure mass, obtained by calculation, leads to a relatively large unfavorable shifting of its COG, necessitating a significant increase in counterweight mass for balancing. A procedure for superstructure 3D model mass correction is presented based on results obtained by weighing after the completion of the erection process. The developed model provides enough accuracy to determine the superstructure's COG in the entire domain of the bucket wheel boom inclination angle, and enables accurate load analysis of the superstructure's vital parts. The importance of this analysis is reinforced by the finding that the procedure prescribed by standard DIN 22261-2 gives results which are not on the side of safety, as shown by an example of strength analysis of a bucket wheel boom stays' end eyes.

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Fatigue life prediction of heavy mining equipment. Part 1: Fatigue load assessment and crack growth rate tests

Cited by 25 publications

References 6 publications

Mechanics of Electric Rope Shovel Performance and Reliability in Formation Excavation

Mechanics of Electric Rope Shovel Performance and Reliability in Formation Excavation

Cable Shovel Stress & Fatigue Failure Modeling - Causes and Solution Strategies Review

Basic parameters of the static stability, loads and strength of the vital parts of a bucket wheel excavator’s slewing superstructure

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