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Simulation of crack propogation of shackle used in suspension gear

Conference Paper · June 2014

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 ABSTRACT: Shackle is widely used as a coupling device in different applications such as tractor’s trolley,
oil exploration, railway, mining etc. Cage shackle is used to connect cage/skip to the mine cage suspension gear
(CSG) through links/chains for transportation of man, material and machines. This paper deals with the crack
propagation of preoccupied cracks under different static load conditions found during quality assessment followed by
FEA.

Keywords: FEA, crack propagation, cage shackle, Magnetic Particle Crack Detection, CSG

1. Introduction

Mine cage suspension gear (CSG) is an assembly of mine hoisting system between cage/skip
and winding rope which is used to raise and lower conveyances safely within the mine shaft.
CSG is used for suspension of cage/ skip for winding in underground mines. It
compris es various components including rope cappel (friction wedge rope cappel or white
metal rope cappel), safety hook, distribution plate, bridle chains and/ or chase block and link
plates as shown in Fig. 1. There are two types of assembly of cage suspension gear (CSG): Single
point and Bridle chain type. In
bridle chain type CSG different
types of shackles are used to
connect different parts, where
cage shackle is used to connect
cage/skip with distribution plate
through chain.

For safe mine operation, it is

mandatory to keep fix factor of
safety (n ) 10 for CSG
components and mining
industries have to follow an
established procedure for their
quality assessment right from
manufacturing to service in the
installation. Before putting in
service CSG components have to
undergo complete quality
assessment. There are two
types of defects in material. Figure 1: Typical Arrangements of Cage Suspension Gear
They are: surface/subsurface
imperfection and internal flaws. There are many NDT methods to assess the quality of
material. CSIR-CIMFR has adopted magnetic particle crack detection for surface/subsurface
imperfection, whereas, ultrasonic flaw detection for internal flaws. Majority of CSG materials
have been failed in magnetic particle crack detection due to surface/subsurface imperfection,
specially, cracks formed due to faulty methods of manufacturing. To mitigate the rejection of
material certain limit of surface imperfections are allowed. These acceptance /rejection norms
have been described in
national/international norms, they are
NCB norms, IS 7587 Part 1:2004 and
DGMS Cir. Tech. 1/2001.
Among CSG components, shackle is the
most critical component. It has been also
observed that shackles are more prone to
surface/ subsurface imperfections and a
number of shackles have been rejected after

Figure 2: Systematic Diagram of Critical Zones of Shackle

magnetic particle inspection. Fig. 2 shows a systematic diagram of critical zones of shackles.
There are two zones in shackle which are considered to be critical that are upper one and bottom
part. Shackle also divides in two regions: shaded and un-shaded. The value of stress
concentration is not constant and varies through the geometry of shackle. The stress
concentration factor is more in shaded zone compare to un-shaded zone, hence their
permissible limit for the lengths of the cracks are different. The crack may be either
longitudinal or transverse. Table 1 shows the permissible limit of t otal cracks length, bot h
longitudinal as well as transverse for a shackle as per different Norms (NCB norms, IS 7587 Part
1: 2004 and DGMS Cir. Tech. 1/2001).

It is felt necessary to mitigate the rejection of shackles by extending the permissible limits of
cracks in the shackle. This paper will draw an attention towards lessening rejection of not only
shackles, but also other CSG components by modifying the acceptance/rejection norms.

Table 1: Permissible Imperfections of Shackle

Permissible Imperfections of Shackle

Part Transverse Longitudinal
Shaded Area None None> 10mm
Un-shaded Area None None> 32mm

2. Methodology

After proof load test (three time safe working load), the specimen was examined on the
magnetic flaw detector for its surface imperfection. For defective specimen, the length of the
cracks were measured and subjected to different tensile loads on it with an increment of 5kN
load. Corresponding to different loads, the length of crack propagation was measured. Crack
propagation was evaluated through solid model of shackle in CATIA v5 R17.

3. Examination of Shackle

In mining industry, Safe Working Load (SWL) of a 50kN cage shackle is 25kN. After proof load
test of 75kN, the respective cage shackle was pass through to magnetic particle crack detection
t est for surface crack evaluation. In this test, five number of cracks were appeared on it,
namely A, B, C, D and E. Out of these cracks A, D and E were longitudinal, whereas, B and C
were mixed in nature i.e. longitudinal as well as transverse. An increment of 5kN load was
applied on the specimen and corresponding length of crack was measured.

After applying 80kN of load, one additional crack propped up labeled as A’ which was mixed
in nature. After applying 85kN of load, three more cracks were appeared namely F, G
and H which were all being longitudinal in nature. The length of cracks were measured each
time and the location of cracks are shown in Fig. 3. Measurement of cracks’ propagation are
listed in Table 2 and one comparison table for length of cracks in shaded & un-shaded region
listed in Table 3. Crack propagation in shaded zone and un-shaded zone are represented in Graph
1 & 2 respectively.
Table 2: Length of Cracks under Different Tensile Loads

Load Crack Length ( mm)

(kN) A A’ B C D E F G H
75 7 --- 8 18 24 22 --- --- ---
80 17 6 10 21 26 24 --- --- ---
85 22 13 10 24 26 25 10 4 3
 90 22 13 10 24 27 25 14 4 4
95 22 13 13 24 27 25 15 4 4
100 22 13 16 24 27 25 18 4 4
Table 3: Comparison between Crack Length in Shaded & Un-Shaded Region

Load Summation of Length of Crack Summation of Length of Crack in

(kN) in Shaded Zone (D+E+F+G+H) Un-Shaded Zone (A+A’+B+C)
75 46 33
80 54 50
85 69 68
90 69 74
95 72 75
100 72 75

Figure 3: Location of Crack Propagation after Load Applied

 Length of Crack(Shaded Zone) Vs Applied Load
120

100

80
Applied Load (kN)

60

40

20

0
0 10 20 30 40 50 60 70 80
Cumulative Length of Crack (mm)

Graph 1: Propagation of Crack in Shaded Zone

Length of Crack(Un-Shaded Zone) Vs Applied Load

120

100
Applied Load (kN)

80

60

40

20

0
0 10 20 30 40 50 60 70 80
Cumulative Length of Crack (mm)

Graph 2: Propagation of Crack in Un-Shaded Zone

4. Finite Element Analysis

Artificially generated cracks on shackle body was performed for finite element analysis in
CAD environment for different case, as discuss below. The solid model of shackle was
generated in CATIA v5R17 part design workbench and, then the solid model was imported in
 Analysis & Simulation workbench. Mechanical properties of material for further analysis is
listed in Table 4.
Table 4: Properties of Material

Material Steel
Young's modulus 2e+011N/m2
Poisson's ratio 0.266
Density 7860kg/m3
Coefficient of thermal 1.17e-005/°K
expansion
Yield strength 2.5e+008N/m2

Case 1: Stress Analysis of shackle with five number of cracks, namely A, B, C, D & E as
observed at 75kN were generated on the solid model of the cage shackle and applied a load of
80kN on it in the Analysis & Simulation workbench. The result of analysis is shown in Figure 4.

Figure 4: Stress Distribution at 80kN Tensile Load

Case 2: Stress Analysis of shackle with six number of cracks, namely A, A’, B, C, D & E as
observed at 80kN were generated on the solid model of the cage shackle and applied a load of
85kN on it in the Analysis & Simulation workbench. The result of analysis is shown in Figure 5.
 Figure 5: Stress Distribution at 85kN Tensile Load

Case 3: Stress Analysis of shackle with nine number of cracks, namely A, A’, B, C, D, E, F, G
& H as observed at 85kN were generated on the solid model of the cage shackle and applied a
load of 90kN on it in the Analysis & Simulation workbench. The result of analysis is shown in
Figure 6.

Figure 6: Stress Distribution at 90kN Tensile Load

Case 4: Stress Analysis of shackle with nine number of cracks, namely A, A’, B, C, D, E, F, G
& H with increasing length of crack as observed at 90kN were generated on the solid model of
the cage shackle and applied a load of 95kN on it in the Analysis & Simulation workbench. The
 result of analysis is shown in Figure 7.

Figure 7: Stress Distribution at 95kN Tensile Load

Case 5: Stress Analysis of shackle with nine number of cracks, namely A, A’, B, C, D, E, F, G &
H with increasing length of crack as observed at 95kN were generated on the solid model of the
cage shackle and applied a load of 100kN on it in the Analysis & Simulation workbench. The
result of analysis is shown in Figure 8. Obtained stress is crossing yield st ress limit and shackle
got permanently deformed.

Figure 8: Stress Distribution at 100kN Tensile Load

Table 5 shows the result of FEA in terms of c u m u l a t i v e of crack length in different

locations (Shaded & Un-shaded) vs Von misses stress (N/mm2). FEA has also been done on
solid model of shackle without crack under different loads ranging from 80kN to 100kN at an
increment of 5kN load. For safe working load, von misses stress is compared with yield stress
value (250MPa). So shackle without crack is safe below 140kN load as is calculated
from mathematical symmetry from Table 5.

Table 5: Von Misses stress in different location

Applied Summation of crack length Von misses stress in N/mm2

load in in mm With crack Without crack
kN Shaded Un-shaded Total Max. value Min. value Max. value Min. value
8 5 8
80 54 50 104 2.31*10 4.66*10 1.46*10 2.39*105
85 69 68 137 2.67*108 5.37*105 1.55*108 2.54*105
90 69 74 143 3.02*108 6.09*105 1.64*108 2.69*105
95 72 75 147 3.38*108 6.81*105 1.73*108 2.84*105
100 72 75 147 3.55*108 7.16*105 1.82*108 2.99*105

Graph 3 shows that total allowable crack length should be within 122mm. In shaded zone
allowable crack length should be within 62 mm as shown in Graph 4, whereas, 60 mm in un-
shaded zone as shown in Graph 5.

CUMUL AT IVE L E NGT H OF CRACKS VS VON

MIS S E S S T RE S S
400
VON MISSES STRESS (MPa)

350
300
250
200
150
100
50
0
0 20 40 60 80 100 120 140 160
CUMULIATIVE LENGTH OF CRACK (mm)

Graph 3: Cumulative Length of Crack Vs Von Misses Stress

L E NGT H O F CRACKS (S H ADE D) VS VO N MIS S E S

S T RE S S
400
VON MISSES STRESS (MPa)

350
300
250
200
150
100
50
0
0 10 20 30 40 50 60 70 80
CUMULIATIVE LENGTH OF CRACK (mm)

Graph 4: Length of Cracks (Shaded) Vs Von Misses Stress

 L E NGT H O F CRACKS (UN -S H ADE D) VS VO N
MIS S E S S T RE S S
400

350
VON MISSES STRESS (MPa)

300

250

200

150

100

50

0
0 10 20 30 40 50 60 70 80
CUMULIATIVE LENGTH OF CRACK (mm)

Graph 5: Length of Cracks (Un-Shaded) Vs Von Misses Stress

5. Conclusions

 This project deals with the behavior of crack propagation of shackle under static load.
 Nondestructive evaluation must be conducted on shackle before placing in service in mine
hoists, so the failure of equipment within prescribed life can be prevented.
 As per Indian Standards & Discard Norms, the permissible length of cracks in regions of
higher stress concentration are less compared to those in regions of higher stress
concentration factor.
 It is also concluded that at 80kN load, generated stress value are less than the yield stress,
hence, shackle remain safe at 80kN load.
 At the safe load condition the summation of crack length is 122 mm is allowable in which
total length in shaded zone is 62mm and in un-shaded zone 60mm.

In Nutshell, permissible limit of surface imperfection mentioned in the relevant standard of CSG
components are need to be revised after study in detail.

Acknowledgement

The authors express their sincere thanks to Dr. A. Sinha, Director, CSIR-CIMFR for his kind
consent in allowing the paper to be published. The views expressed in this paper are of the authors
and not by the institute they belong.

References

[1] Introductory Mining Engineering by Howard L. Hartman, Jan M. Mutmansky

http://media.wiley.com/product_data/excerpt/11/04713485/0471348511.pdf)
[2] http://www.ndt-ed.org/EducationResources/CommunityCollege/Ultrasonics/cc_ut_index.htm
[3] https://www.asnt.org/MajorSiteSections/NDT-Resource-Center/Introduction%20to%20Nondestructive%20Testing
[4] IS 7587 part 1: 2004
[5] IS 7587 part 3: 2006
[6] R. Rahul and Gaji (2012) FEA Based Analysis Of Shackle For Offshore Application,
(IJMIE) ISSN No. 2231 –6477, Vol-2, Iss-4, 2012
[7] http://en.wikipedia.org/wiki/Mining
[8] http://en.wikipedia.org/wiki/Hoist_(mining)
[9] Project report on “Behavior of crack propagation in a duly pre-occupied shackle under
static load by Siddhartha shandilya, Final year B-Tech, Mechanical Engg.
Sikkim Manipal Institute of Technology, May 2012.
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