E410 Design - Lifting Lug and Bracket - Prof. D.

Andrews - January 2008 Introduction During manufacture it is often necessary to lift and move large objects between machining operations. Sometimes this involves an overhead crane, and a sling or lifting attachments would be employed. For safety reasons, such attachments are required to have a limit on the maximum load that can be applied (safe working load). Lifting Lug Design The large plate, shown in Figure 1 (page 2), is an example where a temporary lifting attachment is needed. The plate would ultimately be used with the attachment removed. One approach is to weld on a temporary attachment. The general form of the attachment, known as a lug, is given in Figure 1, but not dimensioned. The lug is welded to one face of the plate, half way along and centred on point A as shown in Figure 1. Lifting would be achieved by a lifting device (e.g. crane) connected to the pin inserted in the lug. Using the material data shown below, together with the plate dimensions given in Figure 1, dimension and give detailed calculations for: (a) The pin diameter (=D) (b) The lug dimensions (H, L, b) (c) The weld of the lug to the plate (A = weld area) Plate Steel Density = 7830 kg/m3 , Pin and lug Mild steel Yield stress = 200 MPa , Weld metal Yield stress = 195 MPa N.B. Other methods of lug design must not be used. Bracket Design If the plate were lifted directly from the pin through the lug then it would not hang vertically. This could make subsequent positioning of the plate for further operations more difficult. In order to avoid this inconvenient it may be important that the plate is lifted vertically. (d) Design a device (bracket) to allow vertical lifting of the plate. Detailed calculations are not required for this part of the exercise.

Stress Analysis For the shear stress in the pin, the tensile stress on the lug net section, the shear stress due to pin pull out from the lug, and the shear stress in the pin, use the following: Stress = Force / Area For pin bending: Extreme fibre stress = 32 M D 3 (2) where M is the bending moment calculated assuming that the pin is in three point bending, with the plate load applied at the centre of the lug, and reacted by the connections to the lifting device on each side of the lug, and D being the pin diameter. For the lug bending: Extreme fibre stress = 6M bd 2 (3) (1)

E410 - Exercise 1 - Deadline: 2 pm on 1st Feb. 08 - www.ucl.ac.uk/~ucemlca/E410 - 1/2

where M is the bending moment calculated using the distance from the pin centre to the plate surface, b is the lug thickness, and d is the lug height measured parallel to the plate. Hints Make the following assumptions: (a) The Tresca yield criterion is appropriate. (b) The safety factor is three. (c) The weld is a fillet weld with equal leg lengths. Use the following simplification: the plate would hang at an angle to the vertical, this makes calculations difficult. To simplify the analysis, carry out separate calculations for the two limiting cases: the full force being parallel to the plate and the full force being perpendicular to the plate. Check the following stresses in the order given. (a) In the pin. The shear stress. The extreme fibre stress due to pin bending. (b) In the lug, for the force in both directions. The tensile stress in the net section. The shear stress due to pin pull out on sections on either side of the pin from the centre line to the surface. (c) In the lug, for the force parallel to the plate. The extreme fibre stress due to lug bending. (d) In the weld connection, for the working load in both directions: perpendicular and parallel to the plate. The shear stress on the minimum area.

Figure 1 - Plate and lifting lug.

E410 - Exercise 1 - Deadline: 2 pm on 1st Feb. 08 - www.ucl.ac.uk/~ucemlca/E410 - 2/2