BOGGIE FRAME - IRCON

MATERIAL HANDLING SYSTEM

DATE – 12/02/15

Design Data:-

Load (P) = 3Ton=3000kg.

Basis of allowable stress UTS/3 & Y.S/1.5 Whichever is lower .

A)

Material = IS-2062

UTS = 410 MPA

410 MPA = 4100 kg/cm2=41kg/mm2

Factor of safety = 3

Allowable stress in tension= 41/3=13.66kg/mm2

Allowable stress in shear (40%)= 5.46 kg/mm2

Allowable stress in bending = 20.4 kg/mm2

Note :- Allowable stress is valid for all operating condition of the plant .

1.) HOIST BEAM WELDED WITH FIXING PLATE CALCULATION :-

MATERIAL – IS-2062

H = 7 mm

L = 1200 mm
Throat Area = .707 x 7 x 1200 = 5938.8 mm2

Stress = Load / Area = 3000/5938.8 = .50 Kg/mm2

Allowable stress in shear = 5.46 Kg/mm2

2.) FIXING PLATE WELDED WITH PART NO.-5

H = 6mm

L = 800 mm

Throat Area = .707 x 6 x 800 = 3393.6 mm2

Stress = 3000 / 3393.6 = 0.88 kg/mm2

3.) BOLTS CALCULATION - M16

HIGH TENSILE BOLT (REFER UNBRACO DATA SHEET)

UTS = 1300N/MM2

FACTOR OF SAFTEY = 5

ALLOAWABLE TENSILE STRESS = 260 N/MM2 = 26 KG/MM2

ALLOWABLE SHEAR STRESS = 104 N/MM2 = 10.4 KG/MM2

Size of bolt = M16

Bore dia = d-2.7 = (16 - 2.7) = 13.3 (FROM PG DATA BOOK)

Area = .785x (D)2 = ..785 x (13.3) x13.3 =138.9 mm2

No. of bolts = 8

Total Area = 138.9 x 8 = 1111.2 mm2

Stress = 3000 / 1111.2 = 2.6 kg/mm2

4.) BENDING MOMENT FOR FIXED BEAM WITH CENTRAL POINT LOAD(PART NO.-5) :-

M = WL / 8 = 1500x 600 / 8 = 112500 KG.MM

CONSIDER 2-ISMC 100x50 SAME AS A SQUARE PIPE 100x100x5THK

So,

I = 271.1 x10000

Z = I / X = 271.1 x10000 / 50 = 54.22x 1000 MM3

BENDING STRESS = M /Z = 112500 / 54.22 x1000 = 2.0 KG/MM2

DEFLECTION IN BEAM

= W x (L)3 / 192 x E x I

= 1500 x ( 600) 3 / 192 x 2.0 x 10000 x 271.10 x 10000

= .0310 mm

5.) TROLLEY FRAME BENDING LOAD CALCULATION

BENDING MOMMENT = W x A = 750x1700 = 1275000 KG.MM

Z = 181 x1000

BENDING STRESS = 1275000 / 181 x1000 = 7.0 KG/MM2

DEFLECTION = PA /24 x E x I 3 (L) 2 -4 (A) 2)

750 x 1700 /24 x 2.0x10000 x1830 x10000x ( 3 x ( 5400) 2 - 4 x (1700) 2 )

11 MM

6.) ROLLER TRACK 50x50

AREA = 50x50=2500 MM2

COMPRESSIVE STRESS = 750 /2500 =.3 KG/MM2

7.) PART NO. 4 & 3 WELDED WITH PART NO. 1 & 6

H= 6MM
L= 2530 x2 =5060MM

Throat Area = .707 x 5060 x 6 =21464

stress = 750 / 21464 =.03 kg/mm2

8.) GUSSET PLATE 6THK x 150 x150

L = 1200

H = 6MM

THROAT ARE = .707 x 6 x1200= 5090.4 MM2

STRESS = 1500 / 5090.4 = .29 KG/MM2

9.) BACK SUPPORT PLATE WELDED WITH FRAME N0 -1 & PART NO.-5

L = 880 MM

H= 6 MM

THROAT AREA = .707 x 880x6 = 3732.96 MM2

STRESS = 1500 / 3732.96 = .40 KG/MM2