Designing A Bucket Mechanism of A Backhoe Loader

DESIGNING A BUCKET MECHANISM OF
A BACKHOE LOADER
A PROJECT REPORT
Submitted by
Alperen KALE
Cantrk SANAN
Fetihhan GRAN
M.Emre PAKSOY
MECHANICAL ENGINEERING DEPARTMENT
HACETTEPE UNIVERSITY
MAY 2015
ABSTRACT
This is the final and third report of the stationary backhoe design project. This project is
combination of both design of systems and selection of systems. Design of systems includes
all the necessary calculations of a mechanical system, such as; static, dynamic, stress, fatigue
analysis so on and so forth. All of the calculations carried out with the help of Statics,
Dynamics, Strength of Materials, Design of Machine Elements and in particular Vehicle
Component Design courses. Selection of systems depends on online part selection tools of
firms and inspection of equivalent systems. These two main design processes combined
together to constitute the proper stationary backhoe for required work conditions with the
comprehensive effort of group members.
Table of Contents
I.
Introduction ......................................................................................................................... 3
A. Problem Statement .......................................................................................................... 3
B. Motivation ....................................................................................................................... 3
C. Challenges and Goals ...................................................................................................... 3
D. Work Plan ........................................................................................................................ 4
II. LITERATURE SURVEY AND PRELIMINARY DESIGN ............................................. 5

A. Literature Survey ............................................................................................................. 5
B. Pugh Chart ....................................................................................................................... 6
C. Design Approach ............................................................................................................. 6
D. Schematic Drawing ......................................................................................................... 7
III.
DESIGN AND SIMULATION ....................................................................................... 9
A.Static Analysis .................................................................................................................. 10

B. Stress Analysis ................................................................................................................. 14
C. Dynamic Analysis ............................................................................................................ 21
D. Fatigue Analysis .............................................................................................................. 23
E. Machine Components Design ....................................................................................... 27
F. Simulation Results ............................................................................................................ 40
Mesh Information - Details................................................................................................... 48
Mesh Control Information: ................................................................................................... 49
G. Cost Analysis ................................................................................................................... 55
H. 3D Drawings .................................................................................................................... 56
IV.
CONCLUSION AND DISCUSSION ........................................................................... 62
A. Summary and Discussion of the Results ......................................................................... 62

B. Future Works ................................................................................................................... 62
V. REFERENCES ................................................................................................................. 63
ii
List of Tables
Table 1 - Task timetable ............................................................................................................. 4
Table 2 - Pugh Chart .................................................................................................................. 6
Table 3 - Cost Table ................................................................................................................. 55
List of Figures
Figure 1 - Free body diagram of the Bucket .............................................................................. 7
Figure 2 - Free body diagram of the Stick ................................................................................. 7
Figure 3 - Free body diagram of the Boom ................................................................................ 8
Figure 4 - Critical points of Factor of Safety ........................................................................... 53
Figure 5 - Critical points of Factor of Safety ........................................................................... 53
Figure 6 - Fatigue analysis and total life .................................................................................. 54
Figure 7 - Static Factor of Safety Critical points ..................................................................... 54
Figure 8 - Side view technical drawing of closed position ..................................................... 56
Figure 9 - Top view technical drawing of closed position ....................................................... 56
Figure 10 - Front and back view technical drawing ................................................................ 57
Figure 11 - Top view technical drawing of opened position.................................................... 58
Figure 12 - Isometric view technical drawing of opened position ........................................... 58
Figure 13 - Isometric view technical drawing of closed position ........................................... 59
Figure 14 - CAD view 1 ........................................................................................................... 60
Figure 15 - CAD view 2 ........................................................................................................... 60
Figure 16 - CAD view 3 ........................................................................................................... 61
iii
I.
Introduction
A. Problem Statement
Stationary backhoes are widely used in almost every mass production sector to carry
products from one place to another effectively. One can examine and find out that these
backhoes are mostly over safe and oversize for most applications. This projects aim is to
design a stationary backhoe which is safe enough, less cost and capable of performing the
duty without any restrictions.
B. Motivation
The basic reason behind this project is to prevent large amount of energy losses which are
produced while the production of these oversize backhoes and during the operation of these
backhoes. Realizing that the most urgent problems of the World are the energy shortage and
the climate change which is directly affected by the energy production methods, even a small
amount of energy gain is very important.
C. Challenges and Goals

Design of this project includes two main parts. The first one is designing a stationary
backhoe with the ability of lifting 500 kg load and the second one is designing necessary
components to run this stationary backhoe. Optimization of the geometry of the backhoe to
reach reasonable factor of safeties and reasonable sizes is the main difficulty, lots of iterations
needed. Another challenging is designation of driver components, there are billions of options
and most effective ones have to be chosen.
Hacettepe University Department of Mechanical Engineering
D. Work Plan
1. Preparing first report and completing literature survey: 1st and 2nd weeks.
2. Completing hand calculations: 3rd and 4th week.
3. Machine components design (Shafts and Bearings): 5th week.
4. Schematic drawings: 6th week.
5. Setting Second Report: 7th week.
6. CAD drawings and FEM analysis: 8th week.
7. Machine components design: 9th week.
8. Technical drawings- Parts list cost analysis: 10th week.
9. Setting final report- Preparing presentation: 11th week.
Table 1 - Task timetable
II.
LITERATURE SURVEY AND PRELIMINARY DESIGN
A. Literature Survey
At the beginning of this project the textbook has been exhaustively examined. A general
idea about for each component has gained by group members. Afterwards applications of
these component has been researched and compared with similar ones. These researches are
made via internet or speaking with the firms at phone.
Some of these sources;
1. How Caterpillar Backhoe Loaders Work
http://science.howstuffworks.com/transport/engines-equipment/backhoe-loader1.htm
2. New Backhoe Loaders CAT 422F
http://www.cat.com/en_ZA/products/new/equipment/backhoeloaders/sideshift/18346265.html
3. CAT Backhoe Loader Brochure
http://s7d2.scene7.com/is/content/Caterpillar/C768535
4. Backhoe Loader
http://en.wikipedia.org/wiki/Backhoe_loader
5. Backhoe
http://opensourceecology.org/wiki/Backhoe
6. SKF Rolling Bearings
http://www.skf.com/binary/138-121486/SKF-rolling-bearings-catalogue.pdf
7. SKF Extra Power Belts
http://www.skf.com/binary/92-118145/Xtra-Power-belts---10552_3-EN.pdf
8. SKF Belt Drive Design Calculations Tool
http://www.skf.com/group/knowledge-centre/engineering-tools/belt-drive-designcalcalutions-tool.html
9. Gamak 3 Phase Asynchronous Electric Motors
http://www.gamak.com/images/urun-pdf/standart_motorlar.pdf
B. Pugh Chart
Reference Design 1
Reference Design 2
Our Design
0
0
0
0
Table 2 - Pugh Chart
C. Design Approach
The basic design approach of this project rely on the motivation of this project. The
sufficient and necessary design method for less energy loss is downsizing. Cost of the project
is another issue that has to be minimized, avoiding from over safe parts will result less energy
loss and less cost. The reliability of this stationary backhoe must be satisfactory so an
optimization is essential between downsizing approach and safety. Such an optimization has
been considered through whole project.
D. Schematic Drawing
1. Free Body Diagram of the Bucket
Figure 1 - Free body diagram of the Bucket
2. Free Body Diagram of the Stick
Figure 2 - Free body diagram of the Stick
3. Free Body Diagram of the Boom
Figure 3 - Free body diagram of the Boom
III.
DESIGN AND SIMULATION
In this part static analysis, dynamic analysis have been made by hand calculations. Also
stress and fatigue analysis have been completed by hand calculations. Assumptions needed to
make analysis are decided after an intense literature survey. A rough sketch of boom, stick
and bucket is completed.
Decision and design of back parts of the system such as electirc motor, shafts and
bearings are made according to necessary power to carry a 500 kg load. The static analysis for
bucket is made in this part.
To begin with, the mass of bucket is assumed as 200 kg and a factor of safety is
considered as 4. The factor of safety is used at the begining of static analysis instead of using
at the end of the stress values consideration.
The desired maximum load is 500 kg. The calculations are made due to this approach,
and therefore the maximum load is taken as 2000 kg. According to this value, the piston
forces and the reactions forces are determined. The formulas and calculations are shown
below.
A. Stat c Analys s
1. Bucket:
Bucket mass
mbucket 200 kg
Mass carr ed by bucket
mload 500 kg
Bucket length
Lbucket 130 cm
Bucket to p ston rod angle
bucket 70
Bucket max. closed angle
b.closed 30
Bucket to p ston d stance
db.p 45 cm
Bucket jo nt d stance
db.j 20 cm
St ck to ground angle
s.g 0
Factor of Safety
FoSbucket 4
P ston 1 Force:
Lbucket
mload FoSbucket + mbucket g
cos b.closed
2
FP1
db.p sin bucket db.j
FP1 = 54.494 kN
Force balance for Jo nt 1 at y ax s:

R1y mload FoSbucket + mbucket g
R1y = 21.575 kN
Force balance for Jo nt 1 at x ax s:

R1x FP1
R1x = 54.494 kN
Hacettepe University Department of Mechanical Enginnering
10
2.St ck:
The mass of st ck, lengths and angles are assumed and g ven below. Due to these
values, the react ons and p ston forces are determ ned.
St ck Length
Lstick 2.6 m
St ck Mass
mstick 200 kg
D stance between st ck and p ston 1
ds.p1 25 cm
P ston 2 to ground angle
p2.g 30
St ck arm jo nt 2 to jo nt 3 d stance
ds.j2.j3 60 cm
P ston 2 Force:
Lstick
mstick g + R1y Lstick FP1 ds.p1
2
FP2
sin p2.g ds.j2.j3
FP2 = 150.067 kN
Force balance for Jo nt 2 at x ax s:

R2x R1x + FP2 cos p2.g FP1
R2x = 129.962 kN
Force balance for Jo nt 2 at y ax s:

R2y R1y + mstick g + FP2 sin p2.g
R2y = 98.57 kN
11
3.Boom:
The mass of boom, shape, lengths and angles are assumed and g ven below. Due to
these values, the react ons and p ston forces are determ ned.
Boom length 1
Lb1 1.5 m
Boom length 2
Lb2 1.7 m
Mass of boom
mboom 350 kg
P ston 3 to groung angle
p3.g 60
P ston 2 perpend cular d stance to jo nt 3
dp2.j3 Lb2 sin p3.g + ds.j2.j3 sin p2.g

dp2.j3 = 1.772 m
Jo nt 2 to jo nt 3 hor zontal d stance
dj2.j3x Lb2 cos p3.g + Lb1 cos p2.g

dj2.j3x = 2.149 m
Jo nt 2 to jo nt 3 vert cal d stance
dj2.j3y Lb2 sin p3.g + Lb1 sin p2.g

dj2.j3y = 2.222 m
dcogb.j3 Lb2 cos p3.g
CoG of Boom to jo nt 3
perpend cular d stance
dcogb.j3 = 0.85 m
dp3.j3 ds.j2.j3 sin p2.g
P ston 3 to jo nt 3
perpend cular d stance
dp3.j3 = 0.3 m
Moment balance for boom:

Mj3 0
mboom g dcogb.j3 + R2y dj2.j3x R2x dj2.j3y + FP2 dp2.j3

FP3
dp3.j3
FP3 = 639.652 kN
12
Force balance for Jo nt 3 at y ax s

R3y R2y + mboom g + FP3 sin p3.g FP2 sin p2.g
R3y = 580.923 kN
Force balance for Jo nt 3 at x ax s

R3x R2x + FP3 cos p3.g FP2 cos p2.g
R3x = 319.826 kN
13
B. Stress Analys s
1.Bucket:
Wbucket 70 cm
W dth of bucket
Abucket Lbucket Wbucket 1.5
Abucket = 1.365 m
mload FoSbucket
bucket
g
Abucket
bucket = 14.369 kPa
S nce the total stress s too small the stress analys s s not necessary. The bucket
w ll not fa l.
2. St ck:
The lengths (w dth, he ght and wall th ckness) of st ck and ts prof le are assumed and
g ven below. Due to these values, the stress analys s s done and the results are shown.
W dth of st ck
wstick 200 mm
He ght of st ck
hstick 150 mm
Wall th ckness of st ck
sstick 10 mm
Jo nt d ameter
Djoint 50 mm
Stress concentrat on factor
Kt.stick 2
Area of st ck:
Astick hstick wstick hstick 2 sstick wstick 2 sstick 2 Djoint sstick
Astick = 0.006 m
Area moment of nert a of st ck:

3
hstick wstick wstick 2 sstick hstick 2 sstick

Istick
12
5
4
I
= 2.33 10 m
stick
14
Ax al Stresses:
FP1 + R1x R2x
a.stick
Astick
a.stick = 23.208 MPa
Bend ng Stresses:
Lstick hstick
hstick
hstick
mstick g
R1y Lstick FP1 ds.p1
2
2
2
2
b.stick +

Istick
Istick
Istick
b.stick = 144.946 MPa
Total Stresses:
tot.stick a.stick + b.stick Kt.stick
tot.stick = 243.477 MPa
3. Boom:
The lengths (w dth, he ght and wall th ckness) of st ck and ts prof le are assumed and
g ven below. Due to these values, the stress analys s s done and the results are shown.
W dth of Boom
wboom 350 mm
He ght of Boom
hboom 300 mm
Wall th ckness of Boom
sboom 30 mm
Stress concentrat on factor
Kt.boom 1.5
Area of Boom
Aboom hboom wboom hboom 2 sboom wboom 2 sboom
Aboom = 0.035 m
15
Area moment of nert a of boom:

3
hboom wboom wboom 2 sboom hboom 2 sboom

Iboom
12
4
4
Iboom = 4.534 10 m
Ax al Stresses:
FP2 + R2x FP3 cos p3.g
a.boom
Aboom
cos p3.g
a.boom = 4.801 MPa
Bend ng Stresses:
hboom FP3 dp3.j3 FP2 dp2.j3 mboom g dcogb.j3 R2y dj2.j3x
b.boom Kt.boom
+
+
+
2
Iboom
Iboom
Iboom
Iboom
b.boom = 143.314 MPa
4. Jo nt between bucket and st ck

Mater al IS2062
Stress l m t for bucket p n
jo nt
max.bpj 205 MPa
Allowable shear stress
bpj 42 MPa
Max mum bear ng pressure
Pbpj 40 MPa
D ameter of bucket p n jo nt
dbpj 50 mm
Length of bucket p n jo nt
Lbpj 300 mm
16
Lbpje 225 mm
Effect ve length of p n jo nt
dbpj
Ymax.bpj
2
Ymax.bpj = 25 mm
2
2
R1y + R1x
R1xy
Bear ng Force of bucket p n

jo nt
Pbpj1 = 5.21 MPa
R1xy = 58.61 kN
R1xy
Pbpj1
dbpj Lbpje
Pbpj1 < Pbpj
It s below max mum bear ng

pressure. So t s ok.
Bucket p n s double shear

2
Abpj 2 dbpj
4
Area of p n bucket jo nt
2
3
Abpj = 3.93 10 m
R1xy
bpj1
Abpj
Shear force act ng on bucket
bpj1 = 14.925 MPa
Un formly d strubuted load

act ng on bucket p n jo nt
bpj1 < bpj
It s below allowable shear

stress. So t s ok.
R1xy
Wbpj
Lbpje
Max mum bend ng moment

occurs at the bucket
Moment of nert a of the

bucket p n jo nt
Wbpj Lbpje
Mbpj
8
Ibpj dbpj
64
N
Wbpj = 260.488
mm
6
Mbpj = 1.648 10 N mm
5
4
Ibpj = 3.068 10 mm
17
Mbpj Ymax.bpj
bpj
Ibpj
Max mum bend ng stress

developped n the bucket p n
bpj < max.bpj
bpj = 134.324 MPa
It s below allowable y eld

strength. So t s ok.
Jo nt between st ck and boom

Mater al IS2062

jo nt
max.spj 205 MPa
spj 42 MPa
Pspj 40 MPa
dspj 75 mm
Lspj 380 mm
Lspje 275 mm
dspj
Ymax.spj
2
Ymax.spj = 37.5 mm
2
2
R2xy
R2y + R2x

jo nt
Pspj1 = 7.909 MPa
R2xy = 163.114 kN
R2xy
Pspj1
dspj Lspje
Pspj1 < Pspj

Bucket p n s double shear

Aspj 2 dspj
4
3
2
Aspj = 8.84 10 m
18
R2xy
spj1
Aspj
spj1 = 18.461 MPa
spj1 < spj

stress. So t s ok.
R2xy
Wspj
Lspje



bucket p n jo nt
Wspj Lspje
Mspj
8
Ispj dspj
64
6
Mspj = 5.607 10 N mm
4
6
Ispj = 1.553 10 mm
Mspj Ymax.spj
spj
Ispj
spj < max.spj
N
Wspj = 593.141
mm
spj = 135.378 MPa

Boom jo nt
Mater al IS2062
jo nt
max.bopj 205 MPa
bopj 42 MPa
Pbopj 40 MPa
dbopj 120 mm
Lbopj 380 mm
285
19
Lbopje 285 mm
dbopj
Ymax.bopj
2
Ymax.bopj = 60 mm
2
2
R3xy
R3y + R3x

jo nt
Pbopj1 = 19.39 MPa
R3xy = 663.144 kN
R3xy
Pbopj1
dbopj Lbopje
Pbopj1 < Pbopj

Bucket p n s double shear;

2
Abopj 2 dbopj
4
3
2
Abpj = 3.93 10 m
R3xy
bopj1
Abopj
bopj1 = 29.317 MPa

bopj1 < bopj

stress. So t s ok.
R3xy
Wbopj
Lbopje
3
N
Wbopj = 2.327 10
mm


bucket p n jo nt
Wbopj Lbopje
7
Mbopj
Mbopj = 2.362 10 N mm
8
Ibopj dbopj
64
Mbopj Ymax.bopj
7
4
Ibopj = 1.018 10 mm
139.258 MPa
20

Mbopj Ymax.bopj
bopj
Ibopj
bopj < max.bopj
bopj = 139.258 MPa

C. Dynam c Analys s
St ck Analys s
To be as s mple as poss ble and as conservat ve as poss ble, one equ l br um

comb ned load s cons dered. Th s cons derat on w ll make stress analys s more
safe s nce one comb nede load at the outer edge of the beam creates h gher
stresses.
mstick
mcombined + mbucket + 4 mload
2
mcombined = 2300 kg
The accelerat on g ven below s angular accelerat on of the st ck on z ax s.

rad
stick.z
8 s2
Accord ng to th s accelerat on, dynam c force analys s has been evaluated:

Fsmax.y mcombined stick.z Lstick + R1y
Fsmax.y = 23.923 kN
Fsmin.y R1y mcombined stick.z Lstick
Fsmin.y = 19.226 kN
21
The angular veloc ty g ven below s the angular veloc ty of the st ck at z ax s.

rad
stick
4 s
Accord ng to th s angular veloc ty, dynam c force analys s has been evaluated:
2
Fsmax.x mcombined stick Lstick + R1x

Fsmax.x = 58.183 kN
Fsmin.x R1x
Fsmin.x = 54.494 kN
Boom Analys s
Same approach wh c has been used for st ck dynam c analys s s also used for
boom analys s.
mboom
mcombined.b mstick + mbucket + 4 mload +
2
mcombined.b = 2575 kg
The accelerat on g ven below s angular accelerat on of the boom on z ax s.

rad
boom.z
8 s2
Accord ng to th s accelerat on, dynam c force analys s has been evaluated:

Lboom 3.09 m
Fbmax.y mcombined.b boom.z Lboom sin (25) + R3y
Fbmax.y = 580.51 kN
Fbmin.y mcombined.b boom.z Lboom sin (25) R3y
Fbmin.y = 581.337 kN
22
The angular veloc ty g ven below s the angular veloc ty of the boom at z ax s.
rad
boom
4 s
Accord ng to th s angular veloc ty, dynam c force analys s has been evaluated:
2
Fbmax.x mcombined.b boom Lboom + R3x

Fbmax.x = 324.734 kN
Fbmin.x R3x
Fbmin.x = 319.826 kN
D. Fat gue Analys s

The selected mater al for th s backhoe appl cat on s AR 235 Steel.
Propert es of AR 235:
Y eld strength
y.235 482.6 MPa
Tens le strength
u.235 792.89 MPa
Endurance l m t
S'e 396.45 MPa
Endurance l m t correlat on factors are set as :
Surface cond t on mod f cat on factor

for mach ned steel
ka 0.88
S ze factor for bend ng
kb 0.667
Work ng cond t ons are always at

reasonable temperatures. So the
temperature factor
kd 1
Rel ab l ty factor for 99%
ke 0.814
M scellaneous effects factor
kf 1
23
Corrected endurance l m t:
Se = 189.418 MPa
Se ka kb kd ke kf S'e
1. St ck Analys s
FP1 + Fsmax.x R2x

a.stick.max
Astick
a.stick.max = 22.549 MPa
Lstick hstick
hstick
hstick
mstick g Fsmax.y Lstick FP1 ds.p1
2
2
2
2
Kt.stick
b.stick.max +
Istick
Istick
Istick
b.stick.max = 329.207 MPa
stick.max b.stick.max + a.stick.max
stick.max = 306.658 MPa
FP1 + Fsmin.x R2x

a.stick.min
Astick
a.stick.min = 23.208 MPa
Lstick hstick
hstick
hstick
mstick g Fsmin.y Lstick FP1 ds.p1
2
2
2
2
b.stick.min +
Kt.stick
Istick
Istick
Istick
b.stick.min = 250.576 MPa
stick.min b.stick.min + a.stick.min
stick.min = 227.369 MPa
Alternat ng stress of cr t cal po nt of st ck:

stick.max stick.min
stick.alt
2
stick.alt = 39.645 MPa
24
Mean stress of cr t cal po nt of st ck:

stick.max + stick.min
stick.mean
2
stick.mean = 267.013 MPa
Soderberg Fa lure Cr ter an:

Fat gue factor of Safety for st ck
Se y.235
nstick.f
stick.alt y.235 + Se stick.mean
nstick.f = 1.311
2. Boom Analys s
FP2 + R2x FP3 cos p3.g

a.boom.max Kt.boom
a.boom.max = 0.843 MPa
Aboom
cos p3.g
Kt.boom 0.41
hboom FP3 dp3.j3 FP2 dp2.j3 mboom g dcogb.j3 Fbmax.y dj2.j3x
+
+
+
b.boom.max Kt.boom
2
Iboom
Iboom
Iboom
Iboom
b.boom.max = 179.652 MPa
boom.max b.boom.max + a.boom.max
boom.max = 178.809 MPa
FP1 + Fbmin.x + R2x

a.boom.min
Astick
a.boom.min = 70.588 MPa
25
hboom FP3 dp3.j3 FP2 dp2.j3 mboom g dcogb.j3 Fbmin.y dj2.j3x

b.boom.min Kt.boom
+
+
+
2
Iboom
Iboom
Iboom
Iboom
b.boom.min = 159.011 MPa
boom.min b.boom.min + a.boom.min
boom.min = 88.423 MPa
Alternat ng stress of cr t cal po nt of st ck:

boom.max boom.min
boom.alt
2
boom.alt = 133.616 MPa
Mean stress of cr t cal po nt of st ck:

boom.max + boom.min
boom.mean
2
boom.mean = 45.193 MPa
Soderberg Fa lure Cr ter an:

Fat gue factor of Safety for st ck
Se y.235
nboom.f
boom.alt y.235 + Se boom.mean
nboom.f = 1.251
NOTE: All the factor of safet es are actually 4 t mes of the r values s nce at the
beg nn ng of the analys s load has taken to be 2000 kg nstead of 500 kg.
26
E. Mach ne Components Des gn

Assumpt ons:
Time for lift ng the bucket to 5m
y5 m
tlift 4 s
y
Vy
tlift
m
Vy = 1.25
s
Power Caluculat ons:
Requ red power n d rect on

of y ax s
y
mstick g
mload + mbucket g y
2
Py
+
tlift
tlift
Py = 9.807 kW
The d stance between the CoG of the bucket and Jo nt 3:

rbucket.x Lb1 sin p3.g + Lb2 cos p3.g + Lstick Lbucket cos b.closed
rbucket.y Lb1 cos p3.g + Lb2 sin p3.g Lbucket sin b.closed
2
2
rbucket
rbucket.x + rbucket.y
rbucket = 3.95 m
The d stance between the CoG of the st ck and Jo nt 3:

Lstick
rstick.x Lb1 sin p3.g + Lb2 cos p3.g +
2
rstick.y Lb1 cos p3.g + Lb2 sin p3.g
2
2
rstick
rstick.x + rstick.y
rstick = 4.103 m
27
The d stance between the CoG of the boom and Jo nt 3:

rboom.x Lb1 sin p3.g
rboom.y Lb1 cos p3.g
2
2
rboom
rboom.x + rboom.y
rboom = 1.5 m
Angular veloc ty:

rad
w
4 s
Angular accelerat on:

rad

8 s2
Moment of Inert as:

Ibucket.p mbucket + mload rbucket
Istick.p mstick rstick
2
3
Istick.p = 3.367 10 kg m
Iboom.p mboom rboom
2
4
Ibucket.p = 1.092 10 kg m
Iboom.p = 787.5 kg m
Act ng toqrue:
Iboom.p + Istick.p + Ibucket.p
= 5919.562 N m
Requ red power to rotate the system n d rect on of z ax s:

Pz w
Pz = 4.649 kW
Total requ red power:

Pdet Py + Pz
Pdet = 14.456 kW
28
Pdet
14.456 kW
Eff c enc es:

mechanical 0.9
hydraulic 0.7
Power of hydraul c motor:

Pdet
P
hydraulic mechanical
P = 22.946 kW
Electric motor efficiency and gearbox efficiency

el.motor 0.91
gb 0.9
P
Pel.motor
el.motor gb
Pel.motor = 28.017 kW
It s assumed that, the backhoe s work ng at a f xed pos t on w th AC electr c ty.

Cons der ng rough calculat ons, the speed of electr c motor s found low. So t s
conven ent to use AC motor w th 8 poles.
Power of electric motor = 30 kw choosen
Propert es of electr c motor:
MARATHON 404 TTFS8102 3 phases, 50 Hz, 30kW, 750 rpm, 91.7% eff.
P 30 kW
N 750 rpm
29
1. Shaft Des gn:
When des gn ng the shaft, s m lar appl cat ons are researched. The
conven ent mater al for th s shaft s determ ned as AISI 440 C steel.
The propert es of shaft are g ven below:
Length of shaft
L2 m
Y eld strength
y 450 MPa
Shear modulus
G 77.2 GPa
Elas c modulus
E 210 GPa
Dens ty
kg
7800
3
m
Shear y eld strength
y 0.5
The clutch may cause mpacts on the shaft so;

n 2.4
Factor of safety
Allowable shear stress:
all
n
all = 93.75 MPa
Max mum torque appl ed on the shaft:

P
T
N
T = 381.972 N m
Shaft d ameter calculat ons:

D ameter
d
16
T
all
d = 2.748 cm
30
The shaft d ameter s assumed as 3 cm;

d 3 cm
Mass of shaft
d
mL
4
m = 11.027 kg
Wmg
We ght of shaft
W = 108.138 N
We ght d str but on
W
wdist
L
Polar moment of nert a
d
J
32
8
4
J = 7.952 10 m
Area moment of nert a
I d
64
4
8
I = 3.976 10 m
Angular deflect on
T L 360
t

JG 2
t = 7.13
Bend ng deflect on
4
5 wdist L
max
384 E I
3
max = 1.349 10 m
Max mum speed

Nmax 0.75
max
Nmax = 610.628 rpm
The max mum speed s lower than requ red speed of shaft. So the new
d ameter s selected as 4 cm
31
d 4 cm
D ameter of shaft
Mass of shaft
d
mL
4
m = 19.604 kg
Wmg
We ght of shaft
W = 192.245 N
We ght d str but on
W
wdist
L
Polar moment of nert a
d
J
32
4
7
J = 2.513 10 m
Area moment of nert a
I d
64
4
7
I = 1.257 10 m
Angular deflect on
T L 360
t

JG 2
t = 2.256
Bend ng deflect on
4
5 wdist L
max
384 E I
4
max = 7.588 10 m
Max mum speed

Nmax 0.75
max
Nmax = 814.171 rpm
Max mum speed s h gher than the requ red speed. So t can be used.
32
2. Bear ng Select on
L fe assumpt on:
It s assumed that the backhoe w ll work 30 years,
9 month per year and 8 hour per day
60
Life 750 30 270 8
6
10
Life = 2.916 10
ka 1.1
because of clutch impact

may occur
W
Fb
2
C
m ll on cycle
kr 1
90% reliability is enough
a3
Life ka Fb
C = 1.511 kN
Bearing selection
Deep groove ball bearing is choosen because of low radial forces
SKF 61808 s choosen

d
D
B
SKF Explorer bearing
40
52
7
C0
4,94
3,45
26000
16000
33
3. Gear and Belt

Np 5500 rpm
Nem 750 rpm
Electr c motors speed s low because of shafts v brat on

restr ct on.
Reduct on rat o
Np
RR
Nem
RR = 7.333
Des gn Cr ter on
RRG 5
Gear part of the reduct on s set to be 5;
So the belt part s;

7.333
RRB
RRG
RRB = 1.467
Nmain = 750 rpm
Nmain Nem
Npinion Nmain RRG
3
Npinion = 3.75 10 rpm
P 30 kW
L 100 10
50 HRC
m 4 mm Assumption
zpinion 20
dpinion m zpinion
dpinion = 80 mm
Npinion
dpinion
dmain
Nmain
dmain = 400 mm
34
b 10 m
b = 40 mm
Assumption between 9m-14m
Spur Gear-Tooth Bending Stress (AGMA)

FOR PINION
dpinion
V Npinion
2
Tpinion
Ft
dpinion
J 0.35
m
V = 15.708
s
P
Tpinion
Npinion
Tpinion = 76.394 N m
Ft = 0.955 kN
From graph
1
Kv From graph
0.6
Km 1.3
Ko 1.25
From Table
From Table 7.4 (small bearing clearances)
Ft
pinion
Kv Ko Km
bmJ
pinion = 46.183 MPa
Assume Cast Iron grade 30 as material of both gear

sf 482 MPa
kL 1
ut 240 MPa
kV 1
ks 0.8
'e 97 MPa
kr 0.814 (%99)
kt 1
kf 1
km 1.33
e 'e kL kV ks kr kt kf km
e = 84.011 MPa
BENDING FOR MAIN GEAR

dmain
V Nmain
2
Tmain
Ft
dmain
m
V = 15.708
s
P
Tmain
Nmain
Tmain = 381.972 N m
Ft = 0.955 kN
35
J 0.35
From graph
1
Kv From graph
0.6
Km 1.3
Ko 1.25
From Table
From Table 7.4 (small bearing clearances)
Ft
Kv Ko Km
main
bmJ
main = 46.183 MPa
this values are same with

pinion
Assume Cast Iron grade 30 as material of both gear

'sf 482 MPa
ut 240 MPa
With hardening 50 HRC assumed

ut
'e
= 832.5 MPa
2
ut 1665 MPa
kL 1
kV 1
ks 0.8
kr 0.814 (%99)
kt 1
kf 1
km 1.33
e 'e kL kV ks kr kt kf km
e = 721.025 MPa
sin (20) cos (20) 5

I
2
6
Cp 149 MPa
H Cp
KL 0.9
0.5
Ft
Kv Ko Km
b dpinion I
KT 1
sf 'sf KL KR KT
H = 339.983 MPa
KR 1
sf = 433.8 MPa
36
4. Hydraulic Calculations for Hydraiulic Pump Selection
To calculate piston volumetric flow rate, piston rods speeds are needed. That
speed is directly depend on speed of bucket , stick and boom. That's why relation
between these speeds must be defined. These relation basically ratio of length piston
arms and parts length (bucket,stick,boom). On this assumption effect of angle
between parts are ignored to easier calculations.
Analysis have been made by pi/4 maximum lifting for boom and stick. But on a
combine movement these speeds will limited to pi/8 for each.
Movement on rotat&onal ax&s' &s not calculated because of these mot&ons w&ll
reduce each other on comb&ne movement to decrease forces that act&ng on arms and
s&ze of pump.
Distance between stick and piston 1
dp1 25 cm
Distance between boom and piston 2
dp2 30 cm
Distance between boom and piston 3
dp3 30 cm
Bucket rotational velocity for lifting motion
rad
wbucket
2
s
Stick rotational velocity for lifting motion
rad
wstick
4 s
Boom rotational velocity for lifting motion
rad
wboom
8 s
Typical pressure for pistons are 300 bar but piston type pumps can reach
420 bar so 400 bar is selected and forces on pistons are already known
from report 2 than;
Hydraulic pressure for pistons
P 400 bar
Forces acting on piston 1
Fp.1 54.494 kN
Fp.2 150.067 kN
Fp.3 639.652 kN
37
Area and bore of pistons are ;

Fp.1
Ap.1
P
Area of piston 1
2
3
Ap.1 = 1.362 10 mm
Dp.1
1
4 Ap.1
Dp.1 = 41.649 mm
Dp.1 45 mm
to standardization
Dp.1
Ap.1
4
Fp.2
Ap.2
P
Area of piston 2
2
3
Ap.2 = 3.752 10 mm
Dp.2
1
4 Ap.2
Dp.2 = 69.114 mm
Dp.2 70 mm
2
Dp.2
Ap.2
4
Fp.3
Ap.3
P
Area of piston 3
Ap.3 = 159.913 cm
Dp.3
1
4 Ap.3
Dp.3 = 142.691 mm
Dp.3 145 mm
2
Dp.3
Ap.3
4
38
Speed and volumetric flow rate of piston rods are ;
Speed of piston rod 1
vp.1 dp1 wbucket
Volumetric flow rate of piston 1
Qp.1 vp.1 Ap.1

L
Qp.1 = 0.625
s
vp.2 dp2 wstick

m
vp.2 = 0.236
s
Qp.2 vp.2 Ap.2

L
Qp.2 = 0.907
s
vp.3 dp3 wboom
Qp.3 vp.3 Ap.3

L
Qp.3 = 1.945
s
Speed of piston 4 (for rotating)
Needed volumetric flow rate for pump selection;
Q Qp.1 + Qp.2 + Qp.3

L
Q = 208.603
min
39
F. Simulation Results
40
Model name: Gen.V2

Current Configuration: Varsaylan
Solid Bodies
Document Name and
Reference
Fillet4
Treated As
Solid Body
Volumetric Properties
Document Path/Date
Modified
Mass:115.931 kg
Volume:0.0147683 m^3
Density:7850 kg/m^3
Weight:1136.12 N
D:\Gen.V2\hyd.cyl\1.SL
DPRT
May 20 01:00:14 2015
Mass:71.1489 kg
Volume:0.00906355 m^3
Density:7850 kg/m^3
Weight:697.259 N
DPRT
May 20 01:00:14 2015
Fillet3
Solid Body
41
Fillet3
Solid Body
Mass:28.0339 kg
Volume:0.0035712 m^3
Density:7850 kg/m^3
Weight:274.733 N
DPRT
May 20 01:00:14 2015
Mass:13.5738 kg
Volume:0.00172914 m^3
Density:7850 kg/m^3
Weight:133.023 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:2.01023 kg
Volume:0.00025608 m^3
Density:7850 kg/m^3
Weight:19.7002 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:7.78129 kg
Volume:0.000991247 m^3
Density:7850 kg/m^3
Weight:76.2566 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:1.27543 kg
Volume:0.000162475 m^3
Density:7850 kg/m^3
Weight:12.4992 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:5.92278 kg
Volume:0.000754494 m^3
Density:7850 kg/m^3
Weight:58.0432 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Fillet1
Solid Body
Fillet1
Solid Body
Fillet1
Solid Body
Fillet1
Solid Body
Fillet1
Solid Body
42
Fillet1
Solid Body
Mass:2.01527 kg
Volume:0.000256723 m^3
Density:7850 kg/m^3
Weight:19.7497 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:5.92278 kg
Volume:0.000754494 m^3
Density:7850 kg/m^3
Weight:58.0432 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:2.27422 kg
Volume:0.000289709 m^3
Density:7850 kg/m^3
Weight:22.2873 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:5.36096 kg
Volume:0.000682924 m^3
Density:7850 kg/m^3
Weight:52.5374 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:2.49617 kg
Volume:0.000317984 m^3
Density:7850 kg/m^3
Weight:24.4625 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:6.29235 kg
Volume:0.000801573 m^3
Density:7850 kg/m^3
Weight:61.665 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Fillet1
Solid Body
Fillet1
Solid Body
Fillet1
Solid Body
Fillet1
Solid Body
Fillet1
Solid Body
43
Fillet1
Solid Body
Mass:7.78129 kg
Volume:0.000991247 m^3
Density:7850 kg/m^3
Weight:76.2566 N
D:\Gen.V2\boom
pin_V2.SLDPRT
May 20 00:39:04 2015
Mass:253.134 kg
Volume:0.0322463 m^3
Density:7850 kg/m^3
Weight:2480.71 N
D:\Gen.V2\boom
rev1_V2.sldprt
May 20 00:39:00 2015
Mass:479.509 kg
Volume:0.0610839 m^3
Density:7850 kg/m^3
Weight:4699.18 N
D:\Gen.V2\boom_V2.SL
DPRT
May 19 17:27:25 2015
Mass:38.6272 kg
Volume:0.00492066 m^3
Density:7850 kg/m^3
Weight:378.546 N
D:\Gen.V2\bucketlink1_
V2.SLDPRT
May 20 00:36:35 2015
Mass:12.1638 kg
Volume:0.00154952 m^3
Density:7850 kg/m^3
Weight:119.205 N
V2.SLDPRT
May 20 00:36:07 2015
Mass:74.7706 kg
Volume:0.00952495 m^3
Density:7849.98 kg/m^3
Weight:732.752 N
V2.SLDPRT
May 20 00:35:41 2015
Fillet27
Solid Body
Fillet25
Solid Body
Fillet5
Solid Body
Fillet1
Solid Body
Fillet4
Solid Body
44
Fillet7
Solid Body
Fillet2
Cut-Revolve2
Fillet2
Cut-Revolve2
Fillet2
Cut-Revolve2
Solid Body
Solid Body
Solid Body
Solid Body
Solid Body
Solid Body
Mass:241.524 kg
Volume:0.0307674 m^3
Density:7850 kg/m^3
Weight:2366.93 N
D:\Gen.V2\myownbucket
2_V2.SLDPRT
May 19 15:47:21 2015
Mass:1.21139 kg
Volume:0.000154317 m^3
Density:7850 kg/m^3
Weight:11.8716 N
D:\Gen.V2\hyd.cyl\Holde
r.SLDPRT
May 20 00:16:58 2015
Mass:44.2107 kg
Volume:0.00563194 m^3
Density:7850 kg/m^3
Weight:433.265 N
D:\Gen.V2\hyd.cyl\Rod.S
LDPRT
May 20 00:24:40 2015
Mass:1.21139 kg
Volume:0.000154317 m^3
Density:7850 kg/m^3
Weight:11.8716 N
r.SLDPRT
May 20 00:16:58 2015
Mass:25.345 kg
Volume:0.00322866 m^3
Density:7850 kg/m^3
Weight:248.381 N
LDPRT
May 20 00:24:40 2015
Mass:1.21139 kg
Volume:0.000154317 m^3
Density:7850 kg/m^3
Weight:11.8716 N
r.SLDPRT
May 20 00:16:58 2015
Mass:7.32229 kg
Volume:0.000932776 m^3
Density:7850 kg/m^3
Weight:71.7584 N
LDPRT
May 20 00:24:40 2015
Mass:349.622 kg
Volume:0.0445379 m^3
Density:7850 kg/m^3
Weight:3426.3 N
D:\Gen.V2\stick
v2_V2.SLDPRT
May 20 00:24:39 2015
Fillet16
Solid Body
45
1. Study Properties
Study name
dinamik
Analysis type
Static
Mesh type
Solid Mesh
Thermal Effect:
On
Thermal option
Include temperature loads
Zero strain temperature
298 Kelvin
Include fluid pressure effects from

SolidWorks Flow Simulation
Solver type
Off
Inplane Effect:
Off
Soft Spring:
Off
Inertial Relief:
Off
Incompatible bonding options
Automatic
Large displacement
Off
Compute free body forces
On
Friction
Off
Use Adaptive Method:
Off
Result folder
SolidWorks document (d:\temp)
FFEPlus
Unit system:
SI (MKS)
Length/Displacement
mm
Temperature
Kelvin
Angular velocity
Rad/sec
Pressure/Stress
N/mm^2 (MPa)
46
2. Loads and Fixtures

Fixture name
Fixture Image
Fixture Details
Entities:
Type:
2 face(s)
Fixed Geometry
Fixed-1
Resultant Forces
Components
Reaction force(N)
Reaction Moment(N.m)
Load name
X
999.291
0
Y
27711.4
0
Load Image
Z
-999.718
0
Resultant
27747.4
0
Load Details
Entities:
Reference:
Type:
Values:
1 face(s)
Edge< 1 >
Apply force
---, ---, 10000 N
Reference:
Values:
Units:
st Dzlem
0 0 -9.81
SI
Entities:
Reference:
Type:
Values:
1 face(s)
Edge< 1 >
Apply force
---, ---, 1000 N
Force-1
Gravity-1
Force-2
47
Entities:
Reference:
Type:
Values:
1 face(s)
Edge< 1 >
Apply force
---, ---, 1000 N
Force-3
3. Mesh Information
Mesh type
Solid Mesh
Mesher Used:
Curvature based mesh
Jacobian points
4 Points
Maximum element size
209.247 mm
Minimum element size
41.8494 mm
Mesh Quality
High
Remesh failed parts with incompatible mesh
Off
Mesh Information - Details

Total Nodes
387530
Total Elements
228594
Maximum Aspect Ratio
235.1
% of elements with Aspect Ratio < 3
66.6
% of elements with Aspect Ratio > 10
3.45
% of distorted elements(Jacobian)
Time to complete mesh(hh;mm;ss):
00:00:29
Computer name:
ALPEREN-PC
48
Mesh Control Information:

Mesh Control Name
Mesh Control Image
Control-1
Control-2
Control-3
Mesh Control Details

Entities:
Units:
Size:
Ratio:
1 Solid Body (s)

mm
44.0919
1.5
Entities:
Units:
Size:
Ratio:
3 Solid Body (s)

mm
17.0118
1.5
Entities:
Units:
Size:
Ratio:
8 Solid Body (s)

mm
37.9869
1.5
49
Entities:
Units:
Size:
Ratio:
Control-4
16 Solid Body (s)

mm
35.9519
1.5
3. Study Results
Name
Type
Min
Max
Stress1
VON: von Mises Stress
3.17023e-005 N/mm^2
(MPa)
Node: 339287
406.808 N/mm^2 (MPa)

Node: 45973
Gen.V2-dinamik-Stress-Stress1
Name
Type
Min
Max
Displacement1
URES: Resultant Displacement
0 mm
Node: 62120
17.9871 mm
Node: 238767
50
Gen.V2-dinamik-Displacement-Displacement1
Name
Type
Min
Max
Strain1
ESTRN: Equivalent Strain
1.62912e-010
Element: 6708
0.00169549
Element: 24045
Gen.V2-dinamik-Strain-Strain1
51
Name
Type
Min
Max
Factor of Safety1
Automatic
1.15534
Node: 45973
1.48254e+007
Node: 339287
Gen.V2-dinamik-Factor of Safety-Factor of Safety1
52
Figure 4 - Critical points of Factor of Safety
Figure 5 - Critical points of Factor of Safety
53
Figure 6 - Fatigue analysis and total life
Figure 7 - Static Factor of Safety Critical points
This is the critical point of the first work. In order to avoid this huge stress concentration, the size
of joints are made bigger and stronger.
54
G. Cost Analysis
From-Brand
self
manufactur
Long Shaft ed
self
Short
manufactur
Shaft
ed
self
manufactur
Gearbox
ed
Belt-drive SKF
Stahl &
Clutch
Eisen
Electric
Motor
Gamak
Hydraulic
Pump
Parker
Bearings
SKF
Driven
Pulley
SKF
Driver
Pulley
SKF
self
manufactur
Boom
ed
self
manufactur
Stick
ed
self
manufactur
bucket
ed
self
manufactur
joints
ed
Casu
cylinders
hydraulic
Properties
Price of
Unit (TL)
Num
ber
Sum
(TL)
40 mm dia, 2 m length, stainless steel
232.32
232.32
40 mm dia, 40 cm length, stainless steel
67.75
67.75
Cast Iron 5:1 ratio

PHG SPZ1202XP
10mm belt width
528
528
40.6
243.6
Dry Plate Clutch
110
110
30 kW 8 poles 750 rpm AC Motor

Pmax 420 bar Nmax 6100 rpm 40
cm^3/rev
61808 deep grove ball bearing
6705
6705
5108
158.6
1
4
5108
634.4
PHP 6SPZ90TB
90mm diameter
182.5
182.5
PHP 6SPZ132TB
132mm diameter
297.6
297.6
480 kg sheet metal and block

metal(Weldment and machining)
3980
3980
350 kg sheet and block metal (Weldment

and machining)
2850
2850
200 kg Sheet metal (bending,weldment

and pressing)
2000
2000
50-200
2000$*2.6
4
12
1440
5280
50-75-100-150mm diameters
45-70-145 mm diameters
Table 3 - Cost Table
55
H. 3D Drawings
Figure 8 - Side view technical drawing of closed position
Figure 9 - Top view technical drawing of closed position
56
Figure 10 - Front and back view technical drawing
57
Figure 11 - Top view technical drawing of opened position
Figure 12 - Isometric view technical drawing of opened position
58
Figure 13 - Isometric view technical drawing of closed position
59
Figure 14 - CAD view 1
60
61
IV.
CONCLUSION AND DISCUSSION
A. Summary and Discussion of the Results

After the implementation of each subsystems to the system, analysis carried out and
results obtained. These results are evaluated and according to them methods has been
developed. The developed methods are depend on the motivation and design approach of this
project. Results are discussed whether the system provides requirements and whether the
system is over safe. If the system turned out to be over safe, downsizing has considered and
applied according to the amount of excess factor of safeties. For the present this system is safe
enough and reliable to perform a lifting of 500 kg.
B. Future Works
In our project the main approach was making the most optimal backhoe with high
speed and low cost. The cost depends on the material. In the future there will be more safer
materials with higher speed ability and lower cost. Also the manufacturing will cost less
because the technology will improve and that will cause decrease in cost. In other projects our
aim will be design a machine with longer life time, with safer material and high ability to
desired approach.
62
V.
REFERENCES
1. How Caterpillar Backhoe Loaders Work

http://science.howstuffworks.com/transport/engines-equipment/backhoe-loader1.htm
2. New Backhoe Loaders CAT 422F
http://www.cat.com/en_ZA/products/new/equipment/backhoeloaders/sideshift/18346265.html
3. CAT Backhoe Loader Brochure
http://s7d2.scene7.com/is/content/Caterpillar/C768535
4. Backhoe Loader
http://en.wikipedia.org/wiki/Backhoe_loader
5. Backhoe
http://opensourceecology.org/wiki/Backhoe
6. SKF Rolling Bearings
http://www.skf.com/binary/138-121486/SKF-rolling-bearings-catalogue.pdf
7. SKF Extra Power Belts
http://www.skf.com/binary/92-118145/Xtra-Power-belts---10552_3-EN.pdf
8. SKF Belt Drive Design Calculations Tool
http://www.skf.com/group/knowledge-centre/engineering-tools/belt-drive-designcalcalutions-tool.html
9. Gamak 3 Phase Asynchronous Electric Motors
http://www.gamak.com/images/urun-pdf/standart_motorlar.pdf
63
Engineering Skills
Firstly this project has improved the engineering skills of all of the group members.
All of the theoretical informations were used in order to get something perceptible. The most
important processes were the problems. Sometimes there was huge problems and it was hard
to solve them. Beacuse of these problems the project did not go easily straight forward. But at
this point all of the group members tried to create a way out and the brain stormings, which
are made during these problems were very important. During this continuum a lot of shiny
idea are took shape and the problems were solved. Besides the problems the technical drawing
and alaysis skills were improved.
This project was a good first step and a great experience for our engineering career.
Its sure that all of us will use these experiences and informations in the future.
64
APPENDICES
A. Sample Cost Analysis
Shaft Manufacturing Analysis
Model ad:
Long Shaft
Rapor tarih ve zaman:
5/20/2015 10:50:37 AM
Malzeme:
Plain Carbon Steel
retim sreci:
Makineleme
Tamamlanm para arl:
55.03 lb
Stok tipi:
Block
Block Size:
1.57x1.57x78.74 in
Malzeme maliyeti/arl:
1.41 USD/lb
Shop Rate:
30.00 USD
retilecek Miktar
Toplam para says:
100
Lot bykl:
100
Para bana ngrlen

88.85 USD
maliyet:
Kullanlan maliyet ablonu:
machiningtemplate_default(englishstandard).sldct
m
Kullanlan maliyet modu:
Manufacturing Process Recognition
Karlatrma:
Maliyet Dalm
Malzeme:
77.59 USD
87%
retim:
11.27 USD
13%
Markup
0.00 USD
0%
Para bana ngrlen

00:22:31
sre:
Kurulumlar:
00:05:35
lemler:
00:16:55
65
Maliyet Raporu
Model Ad:
Part1
Malzeme:
Plain Carbon
Steel
Malzeme maliyeti:
77.59 USD
retim maliyeti:
11.27 USD
Markup
Toplam maliyet
/para:
Toplam sre
/para:
88.85 USD
00:22:31
0.00 USD
retim Maliyet Dalm

lem Ayarlar
Zaman (ss:dd:ss)
Maliyet (USD)
Setup Operation 1
00:00:36
0.30
Toplam
00:00:36
0.30
Zaman (ss:dd:ss)
Maliyet (USD)
Setup Operation 1
00:05:00
2.50
Toplam
00:05:00
2.50
Kurulumlar Ykle ve Kaldr
Yzey
Cilas
karlan Hacim
(in^3)
Zaman
(ss:dd:ss)
Maliyet
(USD)
Volume 1
Roughing
10.48
00:04:13
2.12
Volume 2
Roughing
10.48
00:04:13
2.12
Volume 3
Roughing
10.48
00:04:13
2.12
Volume 4
Roughing
10.48
00:04:13
2.12
41.91
00:16:55
8.47
Freze lemi
Toplam
Aletle
ekillendir
me
Hacim
bana
Maliyet
(USD/in^3)
Flat End
Mill
Flat End
Mill
Flat End
Mill
Flat End
Mill
N/A
N/A
N/A
N/A
Kurulum lemleri
1. Setup Operation 1
a. Volume 4
b. Volume 2
c. Volume 3
d. Volume 1
2
66
B. Belt Specifications
67
68

Designing A Bucket Mechanism of A Backhoe Loader

Uploaded by

Document Information

Original Title

Copyright

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Designing A Bucket Mechanism of A Backhoe Loader

Uploaded by

Copyright:

DESIGNING A BUCKET MECHANISM OF

MECHANICAL ENGINEERING DEPARTMENT

II. LITERATURE SURVEY AND PRELIMINARY DESIGN ............................................. 5

DESIGN AND SIMULATION ....................................................................................... 9

A.Static Analysis .................................................................................................................. 10

CONCLUSION AND DISCUSSION ........................................................................... 62

A. Summary and Discussion of the Results ......................................................................... 62

C. Challenges and Goals

Hacettepe University Department of Mechanical Engineering

Table 1 - Task timetable

Hacettepe University Department of Mechanical Engineering

LITERATURE SURVEY AND PRELIMINARY DESIGN

Hacettepe University Department of Mechanical Engineering

Hacettepe University Department of Mechanical Engineering

1. Free Body Diagram of the Bucket

Figure 1 - Free body diagram of the Bucket

2. Free Body Diagram of the Stick

Figure 2 - Free body diagram of the Stick

Hacettepe University Department of Mechanical Engineering

3. Free Body Diagram of the Boom

Figure 3 - Free body diagram of the Boom

Hacettepe University Department of Mechanical Engineering

DESIGN AND SIMULATION

Hacettepe University Department of Mechanical Engineering

Mass carr ed by bucket

Bucket to p ston rod angle

Bucket max. closed angle

Bucket to p ston d stance

Force balance for Jo nt 1 at y ax s:

Force balance for Jo nt 1 at x ax s:

Hacettepe University Department of Mechanical Enginnering

D stance between st ck and p ston 1

P ston 2 to ground angle

Force balance for Jo nt 2 at x ax s:

Force balance for Jo nt 2 at y ax s:

Hacettepe University Department of Mechanical Enginnering

P ston 3 to groung angle

P ston 2 perpend cular d stance to jo nt 3

dp2.j3 Lb2 sin p3.g + ds.j2.j3 sin p2.g

Jo nt 2 to jo nt 3 hor zontal d stance

dj2.j3x Lb2 cos p3.g + Lb1 cos p2.g

Jo nt 2 to jo nt 3 vert cal d stance

dj2.j3y Lb2 sin p3.g + Lb1 sin p2.g

Moment balance for boom:

mboom g dcogb.j3 + R2y dj2.j3x R2x dj2.j3y + FP2 dp2.j3

Hacettepe University Department of Mechanical Enginnering

Force balance for Jo nt 3 at y ax s

Force balance for Jo nt 3 at x ax s

Hacettepe University Department of Mechanical Enginnering

Abucket Lbucket Wbucket 1.5

bucket = 14.369 kPa

Stress concentrat on factor

Area moment of nert a of st ck:

hstick wstick wstick 2 sstick hstick 2 sstick

Hacettepe University Department of Mechanical Enginnering

a.stick = 23.208 MPa

Wall th ckness of Boom

Stress concentrat on factor

Hacettepe University Department of Mechanical Enginnering

Area moment of nert a of boom:

hboom wboom wboom 2 sboom hboom 2 sboom

a.boom = 4.801 MPa

b.boom = 143.314 MPa

4. Jo nt between bucket and st ck

max.bpj 205 MPa

Allowable shear stress