NCSX

Structural Design Analysis Report

Station 3 HoistLift Fixture,
& Lifting Clevis & Link Pin

NCSX-CALC-18-003-00
April 22May 2, 2008
Prepared By:
___________________________________
Mark Smith, PPPL Mechanical Engineering
Prepared By:
_________________________________________
Srinivas Avasarala, PPPL Mechanical Engineering
Checked By:
________________________________
Art Brooks, PPPL Engineering Analyst
Reviewed By:
________________________________________
Tom Brown, PPPL WBS Tooling Constructability
Reviewed By:
________________________________
Art Brooks, PPPL Engineering Analyst
Reviewed By:
_______________________________________
Mike Viola, PPPL WBS Field Period Assembly

Checked By:
________________________________
Art Brooks, PPPL Engineering Analyst

ii

TCR-ENG-033. R2-002

PPPL

PRINCETON PLASMA
PHYSICS LABORATORY

PROCEDURE

PPPL Calculation Form

No. ENG-033 Rev 2

Attachment 1
Page 1 of 1

PPPL Calculation Form

Calculation # ___NCSX-CALC-18-003-00_____________
_____________

Revision # ______

WP #, if any

(ENG-032)
Purpose of Calculation: (Define why the calculation is being performed.)
Refer to Objective section within the attached report.
References (List any source of design information including computer program titles and revision levels.)
Refer to the Methods and References sections of the attached report.
Assumptions (Identify all assumptions made as part of this calculation.)
Refer to the Methods sections of the attached report.
Calculation (Calculation is either documented here or attached.)
Refer to the attached report.

Conclusion (Specify whether or not the purpose of the calculation was accomplished.)
Yes, the purpose was accomplished. Refer to the Executive Summary in the attached report.
Cognizant Engineers printed name, signature, and date
_____________________________________________________________________
I have reviewed this calculation and to my professional satisfaction, it is properly performed and correct.
Checkers printed name, signature, and data
Printed copies of this document are considered UNCONTROLLED / Information Only copies.

iii

The official document is at http://www.pppl.gov/eshis/PPPL_docs.shtml.

The ES&H and Infrastructure Support Department maintains the signed original.

iv

Executive Summary
Structural analyses provided estimates for the stresses anticipated during proof testing of
the station 3 lift fixture, lifting clevis and link pin. The lift fixture was analyzed for three proof
test configurations. The first configuration, which accounts for the maximum in service load, is
from lift point 1, and requires a proof load of 22.5 kips. Proof loads of 12.6 kips and 17.1 kips
are required for lift points 2 and 3 respectively. Finite element analyses show peak Von Mises
stresses of (19.9-22.8), 6.63, 6.18 ksi for lift points 1, 2, and 3 with corresponding safety factors
of 1.6, 5.4, and 5.8 respectively. The desire was to maximize the usefulness of the lifting clevis
and link pin, by proof testing them at 125% of the actuators load rating. However, the analysis
revealed the link pin is not strong enough to support this load safely. Consequently, the lift clevis
and link pin were analyzed for a capacity rating of 18 kips, which requires a proof load of 22.5
kips. At this load the clevis safety factor is 3.2, failure mode tensile. The link pin safety factors
for contact stress and Von Mises stress are 1.8 and 1.7 respectively. During actual in service use,
(applied load 18 kips) these values are 2.0 and 2.2. The load on the weld is 804 lbf/in. Using a
fillet weld as specified on the drawing provides a safety factor of 6.9.
Structural analyses were performed on the Station 3 hoistlift fixture and lifting clevis.
The objective was to validate safe proof testing conditions through estimating the anticipated
stresses. The hoistlift fixture was analyzed for three proof test configurations. The first
configuration, which accounts for the maximum in service load, is from lift point 1, and required
a proof load of 22.5 kips. Proof loads of 12.6 kips and 17.1 kips are required for lift points 2 and
3 respectively. Finite element analyses show peak Von Mises stresses of (19.9-22.8), 6.63, 6.18
ksi for lift points 1, 2, and 3 respectively. The proof load for the lifting clevis is 40 kips.
Analytical results for the clevis show the maximum stresses are located on section 2 and are:
max tensile stress 19.7 ksi, max shear stress 4.93 ksi, and max bearing stress of 10.2 ksi. The
weld load is 1429 lbf/in.

Need to:

1- Analyze actuator pin/bolt:

a) FEA
v

b) Analytical
2- include allowables in summary.
3- Draw a conclusion.
4- include #3 in executive summary.
5- Edit test to reflect actuator/shackle side.
6- Add equations for weld and analytical computations.
7- insert analysis and modeling filenames: ProE, Ansys, Excel ect.
Clevis:................................................................................................................................................
................................................................................Analysis at Proof load / condition and limits.
...........................................................................................................................................................
.......................................................................................Check/Analysis at in service loads/limits
...........................................................................................................................................................

vi

Table of Contents
PPPL Calculation Form................................................................................................................ii
Executive Summary.....................................................................................................................iii
List of Figures.................................................................................................................................v
List of Tables..................................................................................................................................v
List of Equations............................................................................................................................v
Objective.........................................................................................................................................1
Background....................................................................................................................................1
Methods..........................................................................................................................................2
Lift Fixture Structural Analysis...................................................................................................4
Lift Clevis and Link Pin Analysis.................................................................................................8
Results Discussion........................................................................................................................11
Summary......................................................................................................................................13
References.....................................................................................................................................14
Appendix.......................................................................................................................................15
List of Figures...................................................................................................................................
List of Tables....................................................................................................................................
List of Equations..............................................................................................................................
Background......................................................................................................................................
Lift Fixture Structural Analysis.....................................................................................................
Lift Clevis and Link Pin Analysis...................................................................................................
Results Discussion............................................................................................................................
Lifting Clevis..................................................................................................................................
Link Pin..........................................................................................................................................
Summary..........................................................................................................................................
References.........................................................................................................................................
Appendix...........................................................................................................................................

List of Figures...............................................................................................................................iv
List of Tables.................................................................................................................................iv
List of Equations...........................................................................................................................iv
Background....................................................................................................................................1
Lift Fixture Structural Analysis...................................................................................................2
Lift Clevis Analysis........................................................................................................................7
Summary.......................................................................................................................................11
References.....................................................................................................................................12
Appendix.......................................................................................................................................13

vii

List of Figures
Figure 1. Station 3: Lift Point Layout in Maximum Load Configuration [1]..................................3
Figure 2. Lift Point 1: ProMechanica FEM....................................................................................5
Figure 3. Lift Point 1: ProMechanica FEA Results.........................................................................5
Figure 4. Lift Point 1: Ansys Workbench FEM...............................................................................6
Figure 5. Lift Point 1: Ansys Workbench FEA Results...................................................................6
Figure 6. Lift Point 2: Ansys Workbench FEM & Analysis Results...............................................7
Figure 7. Lift Point 3: Ansys Workbench FEM & Analysis Results...............................................7
Figure 8. Clevis & Link Pin Model.................................................................................................8
Figure 9. Station 3 Lift Clevis Geometry.........................................................................................9
Figure 10. Station 3 Link Pin Geometry..........................................................................................9
Figure 11. Lug & Pin Connection Failure Modes [8]....................................................................10
Figure 12. Non-Linear FEA Results @ 40 kips.............................................................................12
Figure 13. Non-Linear FEA Results @ 22.5 kips..........................................................................12
Figure 14. ASME Reference Geometry [2]...................................................................................15
Figure 15. Pin Shear & Bending Model........................................................................................16
Figure 16. Contact Stress Model...................................................................................................17
Figure 17. Weld Load Model.........................................................................................................17
Figure 1. Station 3: Lift Point Layout in Maximum Load Configuration [1]..................................2
Figure 2. Lift Point 1: ProMechanica FEM....................................................................................4
Figure 3. Lift Point 1: ProMechanica FEA Results.........................................................................4
Figure 4. Lift Point 1: Ansys Workbench FEM...............................................................................5
Figure 5. Lift Point 1: Ansys Workbench FEA Results...................................................................5
Figure 6. Lift Point 2: Ansys Workbench FEM & Analysis Results...............................................6
Figure 7. Lift Point 3: Ansys Workbench FEM & Analysis Results...............................................6
Figure 8. Clevis & Link Pin Model.................................................................................................7
Figure 9. Station 3 Lift Clevis Geometry.........................................................................................8
Figure 10. Station 3 Link Pin Geometry..........................................................................................8
Figure 11. Lug & Pin Connection Failure Modes [8]......................................................................9
Figure 13. ASME Reference Geometry [2]...................................................................................13
Figure 13. Pin Shear & Bending Model.......................................................................................14
Figure 14. Contact Stress Model...................................................................................................15
Figure 15. Weld Load Model.........................................................................................................15
Figure 1. Station 3: Lift Point Layout in Maximum Load Configuration [1]..................................2
Figure 2. Lift Point 1: ProMechanica FEM....................................................................................3
Figure 3. Lift Point 1: ProMechanica FEA Results.........................................................................4
Figure 4. Lift Point 1: Ansys Workbench FEM...............................................................................4
Figure 5. Lift Point 1: Ansys Workbench FEA Results...................................................................5
Figure 6. Lift Point 2: Ansys Workbench FEM & Analysis Results...............................................5
Figure 7. Lift Point 3: Ansys Workbench FEM & Analysis Results...............................................6
Figure 8. Station 3 Lift Clevis CAD Model....................................................................................7
Figure 9. Station 3 Clevis Geometry................................................................................................7
Figure 10. Clevis Tension Loading and Section Labels..................................................................8
Figure 11. Station 3 Lift Clevis FEM...........................................................................................10

viii

Figure 12. Lift Clevis Maximum Von Mises Stress.......................................................................10

Figure 13. ASME Reference Geometry [2]...................................................................................13

List of Tables
Table 1. Material Properties.............................................................................................................3
Table 2. Station 3 Lift Point Proof Loads, Unit Vectors, & Safety Factors.....................................4
Table 3. Clevis Allowable Laods...................................................................................................10
Table 4. Analytical Results Summary............................................................................................10
Table 1. Station 3 Lift Point Proof Loads and Unit Vectors............................................................3
Table 2. Material Properties.............................................................................................................3
Table 3. Material Properties.............................................................................................................7
Table 4. Clevis Allowables..............................................................................................................9
Table 5. Analysis Results Summary...............................................................................................10
Table 1. Station 3 Lift Point Proof Loads and Unit Vectors............................................................3
Table 2. Material Properties.............................................................................................................3
Table 3. Allowable Loads Clevis S1 (a/b).......................................................................................8
Table 4. Allowable Loads Clevis S2................................................................................................8
Table 5. Estimated Clevis Stresses..................................................................................................9

List of Equations
Equation 1. Allowable Pin Tensile Strength: [2] eq (3-45)............................................................15
Equation 2. Effective Width Criteria: [2] eq (3-46).......................................................................15
Equation 3. Effective Width: [2] eq (3-47)....................................................................................15
Equation 4. Allowable Single Plane Fracture Strength: [2] eq (3-48)...........................................15
Equation 5. Allowable Double Plane Shear Strength: [2] eq (3-49)..............................................15
Equation 6. Total Area of Shear Planes: [2] eq (3-50 & C3-2)......................................................15
Equation 7. Allowable Bearing Stress: [2] eq (3-51)....................................................................15
Equation 8. Pin Moment interval [a b].........................................................................................16
Equation 9. Pin Shear interval [b c]...............................................................................................16
Equation 10. Pin Moment interval [b c]:......................................................................................16
Equation 11. Pin Normal Stress from Bending..............................................................................16
Equation 12. Pin Combined Stress: Von Mises [2]........................................................................16
Equation 13. Contact Stress Half Width [6].................................................................................17
Equation 14. Contact Stress Maximum Pressure [6 ]....................................................................17
Equation 15. Weld Load [7]...........................................................................................................17
Equation 1. Allowable Pin Tensile Strength: [2] eq (3-45)............................................................13
Equation 2. Effective Width Criteria: [2] eq (3-46).......................................................................13
Equation 3. Effective Width: [2] eq (3-47)....................................................................................13
Equation 4. Allowable Single Plane Fracture Strength: [2] eq (3-48)...........................................13

ix

Equation 5. Allowable Double Plane Shear Strength: [2] eq (3-49)..............................................13

Equation 6. Total Area of Shear Planes: [2] eq (3-50 & C3-2)......................................................13
Equation 7. Allowable Bearing Stress: [2] eq (3-51)....................................................................13
Equation 8. Pin Moment interval [a b].........................................................................................14
Equation 9. Pin Shear interval [b c]...............................................................................................14
Equation 10. Pin Moment interval [b c]:......................................................................................14
Equation 11. Pin Normal Stress from Bending..............................................................................14
Equation 12. Pin Combined Stress: Von Mises.............................................................................14
Equation 13. Contact Stress Half Width [6].................................................................................15
Equation 14. Contact Stress Maximum Pressure [6 ]....................................................................15
Equation 15. Weld Load [7]...........................................................................................................15
Equation 1. Allowable Pin Tensile Strength: [2] eq (3-45)............................................................13
Equation 2. Effective Width Criteria: [2] eq (3-46).......................................................................13
Equation 3. Effective Width: [2] eq (3-47)....................................................................................13
Equation 4. Allowable Single Plane Fracture Strength: [2] eq (3-48)...........................................13
Equation 5. Allowable Double Plane Shear Strength: [2] eq (3-49)..............................................13
Equation 6. Total Area of Shear Planes: [2] eq (3-50 & C3-2)......................................................13
Equation 7. Allowable Bearing Stress: [2] eq (3-51)....................................................................13

Objective
The objective of this analysis was to validate the design adequacy of the station 3 lift
fixture, lifting clevis and link pin. This validation consisted of determining factors of safety for
the respective components when proof tested. Furthermore, the stress distributions for the lifting
clevis and link pin were investigated at load rating levels of an adjacent rigging componentan
actuator. The aim was to determine whether the clevis and pin load rating could be matched to
the actuator.

Background
Proof testing is required for all in house fabricated lifting components which include the
station 3 hoistlift fixture, lifting clevis and link pin. Safety standards require proof testing at
125% of the maximum anticipated in service load. Previous estimated weight for the half period
(HP) and hoistlift fixture structure is 24 kips [1]. Furthermore, simulation of station 3 field
period assembly (FPA) revealed maximum in service loads of 18 kips, 10.08 kips, and 13.68
kips, for hoistlift fixture lift points 1, 2, and 3 respectively, refer to figure 1 [1]. Therefore, the
required proof test loads for the lift fixture are 22.5 kips, 12.6 kips and 17.1 kips, for lift points 1,
2, and 3 respectively.
The lifting clevis and link pin require a minimum proof testing of at 28.2 kips (125% of
22.5 kips (125% of 18 kips), the maximum anticipated in-service loading.). However, these
components are used in conjunction with an actuator rated from the manufacturer at 50 kips. For
additional safety, PPPL has limited rated the actuator to a maximum load of at 32 kips. Since
versatility is gained when the lift components match in load rating, it is desirable to use the clevis
and pin at the actuator rated value. Therefore, stress levels were investigated for proof testing at
40 kips (125% of 32 kips)..

Methods
The material properties used for this analysis are listed in table 1. For this analysis it was
assumed that the material properties and characteristics are homogenous and uniform throughout
the volumes of the components. Computed Aided Design (CAD) models were created using
ProEngineer software. Finite element models (FEM) were created and finite element analyses
(FEA) were performed using ProMechanica (ProM) and Ansys Workbench (AWB) software.
Furthermore, analytical analysis was performed in Excel based on classical strength of materials
equations. Refer to the references section for the resource list and to the appendix for the
equations used.
Note: ASME BTH-1-2005 Design of Below the Hook Lifting Devices [2] provides the following
comments for evaluation of FEA results used in conjunction with BTH-1-2005.
BTH-1-2005 is based on classical strength of material methods. These
methods effectively compute average stresses acting on structural / mechanical
elements. The effects of stress concentrations are not normally required for static
strength of a lifter, but are most important when determining fatigue life.
Peak stresses due to discontinuities do not affect the ultimate strength of a
structural element unless the material is brittle. The types of steel on which this
Standard is based are all ductile materials. Thus, static strength may reasonably
be computed based on average stresses.
Linear FEA will typically show peak stresses that indicate failure. This is
particularly true when evaluating static strength. While the use of such methods is
not prohibited, modeling of the device and interpretation of the results demands
suitable expertise to assure the requirements of this standard are met without
creating unnecessarily conservative limits for static strength and fatigue life.
Therefore, the NCSX structural standards [3] were used as a basis for evaluating FEA results.
For A36 structural steel with yield strength 36 ksi:
Design Tresca Stress Value (Sm):
Sm equals the lesser of :

(2/3)Yield Strength

= 24 ksi

(1/2)Ultimate Strength

= 29 ksi.

Stress Allowable Primary Stress + Bending Stress Condition: < 1.5Sm

= 36 ksi.

Stress Allowable Total Primary Stress + Seconding Stress Condition: < 3Sm = 72 ksi.
Allowable Bearing Stress < Yield Strength

= 36 ksi.

For HS steel with yield strength 130 ksi:

Design Tresca Stress Value (Sm):
Sm equals the lesser of :

(2/3)Yield Strength

= 87 ksi

(1/2)Ultimate Strength

= 75 ksi.

Stress Allowable Primary Stress + Bending Stress Condition: < 1.5Sm

= 113 ksi.

Stress Allowable Total Primary Stress + Seconding Stress Condition: < 3Sm = 225 ksi.
Allowable Bearing Stress < Yield Strength

Figure 1. Station 3: Lift Point Layout in Maximum Load Configuration [1].

Table 1. Material Properties.
Structural Steel A36
Elastic Modulus:
Tension Yield Strength:
Tension Ultimate Strength:

E = 29.0 E3 ksi
Sty = 36 ksi
Stu = 58 ksi

= 130 ksi.

Lift Link Pin: SAE J429 Grade 8

Elastic Modulus:
Tension Yield Strength:
Tension Ultimate Strength:

29.0 E3 ksi
130 ksi
150 ksi

Hoist Lift Fixture Structural Analysis

A finite element model (FEM) of the hoistlift fixture was created and a linear finite
element analysis (FEA) performed using both ProMechanica and AWB nsys Workbench
software platforms. A ProMechanism simulation of the station 3 field period assembly (FPA)
facilitated vector estimates of the maximum in service loads [1, 4, 5]. FEA was performed at the
loads of 22.5 kips, 12.6 kips and 17.1 kips with corresponding unit vectors for lift points 1, 2,
and 3 respectively. Refer to table 12 for lift point proof loads and unit vectors. and table 2 for the
material properties used in the analysis. Figures 2 and 3 depict the FEA results obtained from
ProMechanica, for lift point 1; figures 4 and 5 represent the results from AWBnsys Workbench.
The ProMechanica results show a peak Von Mises stress of 22.8 ksi The AWB Workbench
results show a peak Von Mises stress of 19.9 ksi. Note, both initial FEMs in ProMechanica and
AWB nsys Workbench revealed peak stresses on the order of 16 ksi. However, by increasing the
nodal count in the region of the peak stress, localized mesh refinement was achieved which
resulted in the higher final results. FEA was performed at lift points 2 and 3 using only the AWB
nsys Workbench platform, figures 6 and 7 display the model and results. FEA for the lift point 2
configuration resulted in a peak Von Mises stress of 6.63 ksi while the lift point 3 configuration
resulted in 6.18 ksi. All peak stresses are below the design Tresca stress value Sm, which is
significantly below the stress allowable. The corresponding safety factors for configurations 1, 2
and 3 are 1.6, 5.4, 5.8 respectively.

Table 2. Station 3 Lift Point Proof Loads, s and Unit Vectors, & Safety Factors.
.

Lift Points: Proof Loads & Unit Vectors.

Lift Point

Load

Magnitude

Safety Factors

ex

ey

ez

Ratio

(lbf)

0.75

22500

0.42

12600

0.57

17100

0.15738
0.24121
0.00966

0.987364

0.018506

1.6

0.967269

0.078798

5.4

0.993034

0.11743

5.8

Lift Points: Proof Loads & Unit Vectors.

Lift Point #
1
2
3

Load Ratio
0.75
0.42
0.57

Magnitude (lbf)
22500
12600
17100

Table 3. Material Properties.

Structural Steel A36
Specific Weight:
Elastic Modulus:
Rigid Modulus:

ex
-0.15738
-0.24121
-0.00966

ey
0.987364
0.967269
0.993034

= 0.284 lbf/in3
E = 29.0 E3 ksi
G = 11.0 E3 ksi

Tension Yield Strength:

Compression Yield Strength:

Sty = 36 ksi
Scy = 36 ksi

Tension Ultimate Strength:

Compression Ultimate Strength:

Stu = 58 ksi
Scu = 58 ksi

Figure 2. Lift Point 1: ProMechanica FEM.

ez
0.018506
0.078798
0.11743

Figure 3. Lift Point 1: ProMechanica FEA Results.

Figure 4. Lift Point 1: Ansys Workbench FEM.

Figure 5. Lift Point 1: Ansys Workbench FEA Results.

Figure 6. Lift Point 2: Ansys Workbench FEM & Analysis Results.

Figure 7. Lift Point 3: Ansys Workbench FEM & Analysis Results.

Lift Clevis and Link Pin Analysis

Analytical calculations and non-linear FEA were performed for the lift clevis and link
pin, first based on the actuator load rating and then based on the maximum expected in-service
loading. to determine proof test stress levels and establish allowable loads. Refer to the appendix
for the equations used. Refer to fFigure 8 depicts the CAD for a model of the clevis and pin. and
tables 2 and 3 list for the material properties used in thise analysis. Note, figure 8 contains a
portion of the actuator and also a a shackle pin. Both of theseThis is a are commercial items and
are load load rated per the manufacturer. Therefore, it was these parts were not analyzed, but was
ere included for visual reference only. Figure 9 provides the clevis geometry and figure 10 the
link pin. There are 4Four failure modes are possible for the clevis: tension, splitting, shear, and
dishing, refer to figure 11 [8]. and There are two 2 failure modes for the link pin: shear and
bending. refer to figure 11 [8]. Per ASME [2], analysis for the dishing failure mode,, figure 11d,
is accounted for in the standard. can be ignored. Table 43 lists the allowable loads calculated for
the clevis determined via based the ASME [2] guidelines. , reference the appendix for the
equations.Table 54 provides a summary of the analytical results, (safety factors based on yield)
and figures 12 and 13 depict the results of the FEA. load analysis. Note, three loading levels
were evaluated. The first was 40 kips, and was used to evaluate if the clevis and pin could be
loaded at the actuator maximum rating of 32 kips. The analysis revealed this was not possible.
Consequently, additional analyses were performed in order to determine the maximum proof test
load. This is 39 kips. The third load level reflects the maximum anticipated in service load and is
included to provide insight into the in service stress levels.

Table 4. Material Properties.

Lift Link Pin: SAE J429 Grade 8
Elastic Modulus:
Tension Yield Strength:
Tension Ultimate Strength:
Poisson's Ratio

29.0 E3 ksi
130 ksi
150 ksi
0.32

Actuator
Actuator

Clevis
Clevis

LinkLink
Pin Pin

Shackle Pin
Shackle Pin

Figure 8. Clevis & Link Pin Model.

10

Figure 9. Station 3 Lift Clevis Geometry.

Figure 10. Station 3 Link Pin Geometry.

11

Figure 11. Lug & Pin Connection Failure Modes [8].

Table 5. Clevis Allowables.Table 6. Clevis Allowable Laods.

Clevis Section 1a/b
Pt1
118320
Pb1
85153
Av1
4.816
Pv1
81463
Clevis Section 2
Pt2
176719
Pb2
141997
Av2
8.354
Pv2
141317

lbf
lbf
in^2
lbf

Allowable Tensile Strength through Pin Hole

Allowable Single Plane Fracture Strength beyond Pin Hole
Total Area of Shear Planes beyond Hole. *NOTE: curved edges
Allowable Double Plane Shear Strength beyond Pin Hole.

lbf
lbf
in^2
lbf

Allowable Tensile Strength through Pin Hole.

Allowable Single Plane Fracture Strength beyond Pin Hole
Total Area of Shear Planes beyond Hole. *NOTE: curved edges
Allowable Double Plane Shear Strength beyond Pin Hole.

CAD Model Parameters: Section 1a/b

Pt1
Pb1
Av1
Pv1

118320
85153
4.816
81463

lbf
lbf
in^2
lbf

Allowable Tensile Strength through Pin Hole

Allowable Single Plane Fracture Strength beyond Pin Hole
Total Area of Shear Planes beyond Hole. *NOTE: curved edges
Allowable Double Plane Shear Strength beyond Pin Hole.

lbf
lbf
in^2
lbf

Allowable Tensile Strength through Pin Hole.

Allowable Single Plane Fracture Strength beyond Pin Hole
Total Area of Shear Planes beyond Hole. *NOTE: curved edges
Allowable Double Plane Shear Strength beyond Pin Hole.

CAD Model Parameters: Section 2

Pt2
Pb2
Av2
Pv2

176719
141997
8.354
141317

12

13

Table 7. Analysis Results Summary.Table 8. Analytical Results Summary.

Component
Component
Clevis Section S1a/b
Clevis Section S1a/b

Clevis Section S2
Clevis Section S2

Weld (S.F. @ 1/2 inch)

Weld
LinkPin-Clevis
Pin-Clevis
Link
LinkPin-Actuator
Pin-Actuator
Link
LinkPin
Pin
Link

Stress Type
Stress Type
Tensile Stress Net (psi)
Tensile Stress Net (psi)
Max Tensile Stress (psi)
Max Tensile Stress (psi)
Shear Stress (psi)
Shear Stress (psi)
Bearing Stress (psi)
Bearing Stress (psi)
Tensile Stress Net (psi)
Tensile Stress Net (psi)
Max Tensile Stress (psi)
Max Tensile Stress (psi)
Shear Stress (psi)
Shear Stress (psi)
Bearing Stress (psi)
Bearing Stress (psi)
load(lbf/in)
(lbf/in)
load
BearingStress
Stress(psi)
(psi)
Bearing
ContactStress
Stress(psi)
(psi)
Contact

Appplied Loading
40 kips
22.5 kips
18 kips
40 kips
18 kips
4085
3077
1838
4085
1838
14297
8042
6434
14297
6434
4153
2336
1869
4153
1869
7273
4091
3273
7273
3273
5470
3077
2462
5470
2462
19692
11077
8862
19692
8862
4788
2693
2155
4788
2155
10907
6135
4908
10907
4908
1429
804
643
1429
643
7273
4091 3273 3273
7273
69181
51885 46408 46408
69181

BearingStress
Stress(psi)
(psi)
Bearing
ContactStress
Stress(psi)
(psi)
Contact

12929
12929
94945
94945

7273 5818 5818

71209 63691 63691

ShearStress
Stress(psi)
(psi)
Shear
VonMises
Mises(psi)
(psi)
Von

13469
13469
132241
132241

7576 6061 6061

74386 59508 59508

14

Safety Factor at
22.5 kips
18 kips

11.7
4.5
15.4
8.8
11.7
3.2
13.4
5.9
6.9
31.8
2.5
17.9
1.8
17.2
1.7

19.6
5.6
19.3
11.0
14.6
4.1
16.7
7.3
8.7
39.7
2.8
22.3
2.0
21.4
2.2

Results Discussion

Lifting Clevis
Often, lifting components are forged or cast parts. Subsequently, a higher confidence is
retained when material property assumptions are applied to these parts, i.e. homogenous, uniform
etc. In contrast, material properties in weld heat affected zones can not be assumed with high
confidence. The lifting clevis, made from A36 structural steel, is a welded item as specified by
drawing se185-317. Consequently, the previous material property assumptions for the clevis are
limited..
The desire was to maximize the usefulness of the lifting clevis and link pin by proof
testing them at 40 kips, (125% of the actuators PPPL load rating of 32 kips.) Examining the
computed clevis load limits, table 3, it is clear the clevis has sufficient strength to carry this load
safely. However, the analysis revealed the Von Mises stress exceeded the link pin yield strength.
A non-linear FEA was performed on the link pin which revealed lower Von Mises stresses when
compared to the previous results, see figure 12. However note, the FEA results still show
significant stress levels in the pin. The classical methods of analysis are more conservative, but
reliable. In addition, the ASME standard [2] is based these methods. Therefore, the lift clevis and
link pin were analyzed for a lower rated capacity. This rating is based on the maximum
anticipated in-service load of 18 kips, which requires a proof load of 22.5 kips. Table 4 lists the
analytical results and figure 13 depicts the FEA results. The strength limiting area on the clevis is
section S2, failing via maximum tensile stress, safety factor of 3.2. The link pin safety factors for
contact stress and Von Mises stress are 1.8 and 1.7 respectively. During actual in service use,
(applied load 18 kips) these values are 2.0 and 2.2. The load on the weld is 804 lbf/in. Using a
fillet weld as specified on the drawing provides a safety factor of 6.9.

Consequently, material properties in the weld heat affected zone can not be assumed with high
confidence. The analysis reveals the clevis is sized sufficiently. Referring to table 4, the
allowable loads are for: mode 1 failure 118 kips, mode 2 failure 85 kips, and mode 3 failure 81

15

kips. These values are well above the desired proof load and anticipated in service loads,
providing a safety factor of 4.07 for proof loading and 6.5 for in service loading. The bearing
stress guidelines used were not intended as a strength limit, but serve to control deformation and
wear of the plate [2]. The bearing stress limit is 22500 ksi. Maximum clevis bearing stress, refer
to table 5, is 10.9 ksi located in clevis section S2. This provides a bearing stress safety factor of
2.06.

Link Pin

16

Figure 12. Non-Linear FEA Results @ 40 kips.

Figure 13. Non-Linear FEA Results @ 22.5 kips.

17

18

1.

Discussion

2.
3.
4. Mention concerns about weld effects on clevis.
5.
6. Recommend DO NOT WELD the nut to the link pin.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

19

31.

32.
Summary
Structural analyses provided estimates for the stresses anticipated during hoist proof
testing of the station 3 lift fixturestructure, lifting and clevis. and link pin. The lift fixture was
analyzed for three proof test configurations. The first configuration, which accounts for the
maximum in service load, is from lift point 1, and requires a proof load of 22.5 kips. Proof loads
of 12.6 kips and 17.1 kips are required for lift points 2 and 3 respectively. Finite element
analyses show peak Von Mises stresses of (19.9-22.8), 6.63, 6.18 ksi for lift points 1, 2, and 3
with corresponding safety factors of 1.6, 5.4, and 5.8 respectively. The hoistlift fixture was
analyzed for three proof test configurations. The first configuration from lift point 1, which
accounts for the maximum in service load, required a proof load of 22.5 kips and resulted in a
peak stress of 19.9-22.8 ksi. Configuration 2, lift point 2, required a proof load of 12.6 kips and
resulted in a peak stress of 6.63 ksi. Configuration 3, from lift point 3, required 17.1 kips and
resulted in a peak stress of 6.18 ksi. The lifting clevis is proof tested at 40 kips. Analytical stress
computations revealed maximums of 19.7, 4.93, 10.2 ksi for tensile, shear, and bearing stresses
respectively. The weld load is 1429 lbf/in, and using the designed fillet weld of inch provides a
weld safety factor 3.9.

The desire was to maximize the usefulness of the lifting clevis and link pin, by proof
testing them at 125% of the actuators load rating. However, the analysis revealed the link pin is
not strong enough to support this load safely. Consequently, the lift clevis and link pin were
analyzed for a capacity rating of 18 kips, which requires a proof load of 22.5 kips. At this load
the clevis safety factor is 3.2, failure mode tensile. The link pin safety factors for contact stress
and Von Mises stress are 1.8 and 1.7 respectively. During actual in service use, (applied load 18
kips) these values are 2.0 and 2.2. The load on the weld is 804 lbf/in. Using a fillet weld as
specified on the drawing provides a safety factor of 6.9.

20

References
1. Brown, T. Analysis performed on the FPA station 3 lift fixture for its FDR
NCSX-CALC-18-002-00. 10 Dec. 2007.
2. ASME. BTH-1-2205 Design of Below the Hook Lifting Devices. 2006.
3. Zatz, I. J., NCSX Structural Design Criteria NCSX-CRIT-CRYO-00. 2004.
4. Brown, T. Excel File: trace00_path5tom3r13right.xls.
5. ProMechanism Simulation Files: stb-fpa_mech_leftside.asm, stb-fpa_mech_rightside.asm.
6. Shigley. Machine Design 7th ed. 2004.
7. Blodgett, O, W. Design of Welded Structures. 1966.
8. Duerr, D. Pinned Connection Strength and Behavior. 2006. Journal of Structural Engineering.
Feb. p 182-194.

21

Appendix
Refer to figure 1434 for applying equations 1-67.
Equation 1. Allowable Pin Tensile Strength: [2] eq (3-45).

Pt

Fu
2tbeff
1. 2 N d

Equation 2. Effective Width Criteria: [2] eq (3-46).

beff 4t be

Equation 3. Effective Width: [2] eq (3-47).

beff be 0.6

Fu
Fy

Dh
be
be

Equation 4. Allowable Single Plane Fracture Strength: [2] eq (3-48).

Fu
Pb
1.2 N d

Dh
0.92be

1.13 R 2
t
b
e

Dh

Equation 5. Allowable Double Plane Shear Strength: [2] eq (3-49).

Pv

0.70 Fu
Av
1.2 N d

Equation 6. Total Area of Shear Planes: [2] eq (3-50 & C3-2).

D sin 45
D

Av 2t R h cos 45 r r 2 h

2
2

Figure 14. ASME Reference Geometry [2].

Equation 7. Allowable Bearing Stress: [2] eq (3-51).

22

1.25Fy

Fp

Nd

Figure 15. ASME Reference Geometry [2].

Figure 16. ASME Reference Geometry [2].

Refer to figure 135 for applying equations 8-12.

Actuator

T/2

Link Pin
x1 x2
T/2
Clevis
a
T/2

1.125 in

1 in

1.25 in

x1 = [a
b]

+M
+P

T/2

1 in
x2 = [b
c]

+V
+M
+P

1.125 in

23

+V

Figure 17. Pin Shear & Bending Model.

Figure 18. Pin Shear & Bending Model.

Equation 8. Pin Moment interval [a b].

T
M x1
1 x1
2
Equation 9. Pin Shear interval [b c].

T
T
V x 2 x 2

2
2.25
Equation 10. Pin Moment interval [b c]:

x2 T
T
M x 2 1.125 x 2 2

2
2 2.25
Equation 11. Pin Normal Stress from Bending.
f cr

f x2 f x f y f y2 3 f v2

Mc

x fx

Equation 12. Pin Combined Stress: Von Mises [2].

f cr

f x2 f x f y f y2 3 f v2

Refer to figure 146 for applying equations 13 and 14 and figure 175 for equation 15.

d2

2b
L
F
d1

Figure 19. Contact Stress Model.

Figure 20. Contact Stress Model.

24

Equation 13. Contact Stress Half Width [6].

2F
l

1
2
1

E1

1
2
2

E2

1 1
d1
d2

Equation 14. Contact Stress Maximum Pressure [6 ].

p max

2F
bl

Figure 21. Weld Load Model.

Figure 22. Weld Load Model.
Equation 15. Weld Load [7].

Load weld

25

T
Force
2

Area weld 2b 2d