Project Overview

The objective of this study was to conduct a comprehensive static structural and buckling analysis on a 35-ton beam assembly suspended by four slings with magnets at the bottom face. The goal was to evaluate the deformation, stress distribution, axial forces on the bolts, and the load factor at buckling.

Scope of Work

1. Deformation and Stress Analysis: Assessing deformation and stress at different parts of the beam.

2. Axial Forces on Bolts: Estimating the forces on 56 bolts due to beam buckling.

3. Buckling Load Factor: Determining the critical buckling load factor for the assembly.
   
   
   

Analysis Methodology

We applied a structured strategy to analyze the entire system.

Assembly Level Study & Geometry Considerations

• A virtual model of the beam assembly was created for analysis.

• Mesh generation was performed to ensure connectivity and accuracy.
  
  
  

Mesh Details

• Number of Nodes: 334,547

• Number of Elements: 169,471

• Mesh Type: Tetrahedral mesh ensuring computational efficiency and accuracy.
  
  
  

Boundary Conditions

• Virtual slings were connected at a remote point 3200 mm above the top surface of the beam to simulate real-world conditions.
  
  
  

Key Findings

Deformation Analysis

• Maximum Deformation: 9.92 mm observed at both ends of the beam.

• The deformation behavior was as expected, confirming the reliability of the model.
  
  
  

Stress Analysis

• Maximum von-Mises Stress: 91.572 MPa (Singular stress and negligible).

• Average Stress Near Maximum Zone: 50 MPa.

• Yield Strength: 250 MPa.

• Safety Factor: Greater than 4, indicating a structurally sound design.
  
  
  

Axial Forces on Bolts

• 56 virtual bolts were analyzed to estimate axial forces.

• Due to symmetry, the right-side bolts experienced identical forces to the left-side bolts.

• Maximum axial force observed was approximately 27,589 N.
  
  
  

Eigenvalue Buckling Analysis

• Two buckling modes were detected near the hooks.

• The load multiplier was found to be nearly 50, confirming structural stability against buckling failure.

Conclusion & Recommendations

• The beam assembly is structurally stable under the given loading conditions.

• The deformation and stress levels remain well within safe limits, with a high safety factor.

• The buckling analysis confirms no immediate risk of failure.

Future Recommendations:

• Further optimization of bolt positioning can be considered for additional load distribution efficiency.

• Implement additional localized reinforcements if higher loads are anticipated.

This study confirms that the 35T beam assembly is safe and structurally robust for operational use.

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