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Rev.: Date: Description: Made by: Checked by: Approved :
Document title:

TUGGER SHEAVE, WIRE PULL 40T

Customer: Document number:

D-240-02
Project Number: In connection with customer doc. No. : No. of pages
240 15-16-0001 Layout
Revision status: Published: Made By:
Contents

1. Introduction ........................................................................................................................ 3
2. General information............................................................................................................ 4
2.1 Material model ....................................................................................................................... 4
2.2 Model information.................................................................................................................. 4
3. FEM Analysis ....................................................................................................................... 7
3.1. Fixtures ......................................................................................................................... 7
3.2 Loading .......................................................................................................................... 8
3.3 Mesh.............................................................................................................................. 9
3.4 Stress Results .............................................................................................................. 10
3.5 Deformation Results ................................................................................................... 20
4. Conclusion ......................................................................................................................... 21
5. Appendix ........................................................................................................................... 21

Page 2 of 21
1. Introduction

FEM analysis of “tugger” sheave was conducted to get insight into structural integrity
of its parts under working conditions, which are defined with GA drawing delivered by
costumer. As a load was used 40 t rope pull force multiplied by 1.3 Dynamic Amplitude
Factor (DAF) recommended by DNV and their standard 2.22. To obtain convergence of
study some simplifications of assembly were done.

Tugger sheave assembly was analyzed for 2 sheave positions (figure 1):

• LC1 – sheave rotated for 90° from neutral position;

• LC2 – sheave in neutral position.

Figure 1 – Position of sheave while loading

For forces, bearings and screw connection calculations refer to Appendix A1.

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2. General information

2.1 Material model

Majority of roller parts was made from S355 steel grade, material properties are
shown in table 1.

Modulus of Poisson Yield

Material Density Tensile
elasticity ratio stress
S355J2G3 7850 kg/m3 210 000 N/mm2 0,27 355 MPa 630 MPa
SS2387 7700 kg/m3 215 000 N/mm2 0,27 750 MPa 950 MPa

Table 1 – Material Properties

All welds assumed to be all around or with full penetration. Weld throat thickness to
be minimum 70% of minimum plate thickness within weld joint.

For bearing material properties please refer data sheet in Appendix A2.

2.2 Model information

Part Description Drawing No. Material Image

PLATE
13-16-0020-01 S355J2G3
(Thickness: 25 mm)

4xPLATE
13-16-0020-02 S355J2G3
(Thickness: 40 mm)

2xPLATE
13-16-0020-03 S355J2G3
(Thickness: 25 mm)

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 2xPLATE
13-16-0020-04 S355J2G3
(Thickness: 25 mm)

2xPLATE
13-16-0023-01 SS2387
(Thickness: 25 mm)

2xPLATE
13-16-0023-02 SS2387
(Thickness: 20 mm)

2xPLATE
13-16-0023-03 S355J2G3
(Thickness: 20 mm)

2xPLATE
13-16-0023-04 S355J2G3
(Thickness: 20 mm)

PLATE
13-16-0023-05 S355J2G3
(Thickness: 20 mm)

PLATE
13-16-0023-06 S355J2G3
(Thickness: 15 mm)

PIPE
N/A S355J2G3
(Ø220/Ø150 mm)

Page 5 of 21
FOUNDATION BOLT
13-16-0021 SS2387
(Ø120/Ø250 mm)

SHEAVE BOLT
13-16-0014 S355J2G3
(Ø100/Ø255 mm)

2xAXIAL SLIDE
BEARING 13-16-0024 JM5
(Ø220/Ø122X7 mm)

2xRADIAL SLIDE
BEARING 13-16-0027 JM5
(Ø130/Ø120X135 mm)

Table 2 – Model Information

Page 6 of 21
3. FEM Analysis
3.1. Fixtures

To simplify FEM analysis setup as possible screw connection was neglected in this
study, construction of tugger sheave assembly was fixed on foundation flange as shown on
figure 2. Same fixture was applied in both load cases LC-1 and LC-2.

Figure 2 – Fixture

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3.2 Loading

As a load was used resultant force calculated for worst case of rope position. As a
loading tool was used “Remote Force”, see figure 3, placed on half sheave pitch circle
diameter distance from sheave center with direction determined graphically. For calculation
and graphic orientation of resultant force see Appendix A1. Sheave assembly and its parts
were replaced with point of mass placed in the bolt center, also standard earth gravity were
added as a load, see figure 3.

Figure 3 – Loading

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3.3 Mesh

Same mesh properties were applied in both load cases.

Figure 4 – Mesh

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3.4 Stress Results

3.4.1 Load Case 1

Figure 5 – Stress Results – Complete Assembly

From figure 5 it is visible that highest stress is close to 2000MPa which is above
allowed value of yield strength for S355 steel grade. To get better insight into stress
concentration areas and its locations all main parts of assemblies will be observed
separately, and results are shown on following figures.

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 Figure 6 – Stress Results – Foundation Assembly

Figure 7 – Stress Results – Foundation Assembly (DETAIL B, figure 6)

Page 11 of 21
 Figure 8 – Stress Results – Foundation Assembly (Cleared values bellow 300MPa)

From figures 6, 7 and 8 it is visible that high stress value is located in very small area.
This high stress is caused by complex geometry of foundation in this area (small radius) and
by size of mesh element which is not small enough. Majority of foundation assembly parts
have stress values bellow 300MPa, which is value of approx. 85% of yield strength for S355
steel grade. It is important to notice here that welds are neglected because of simplification
of a study, so in reality stress values will be even more reduced.

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Figure 9 – Stress Results – Foundation Assembly

Figure 10 – Stress Results – Sheave Housing

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 Figure 11 – Stress Results – Sheave Housing

Figure 12 – Stress Results – Sheave Housing (Detail C)

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 Figure 13 – Stress Results – Sheave Housing (Cleared values bellow 300MPa)

Figure 14 – Stress Results – Sheave Housing

(Deformation scale highly increased to get insight in to behavior under loading)
Page 15 of 21
 In a case of sheave housing high stress values are located in areas where geometry is
complex and mesh quality is not good enough to obtain a correct results. Majority of sheave
housing has stress values bellow 300MPa.

3.4.2 Load Case 2

Figure 15 – Stress Results – Complete Assembly

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 Figure 16 – Stress Results – Foundation Assembly

Figure 17 – Stress Results – Foundation Assembly (Cleared values bellow 300MPa)

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Figure 18 – Stress Results – Sheave Housing

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 Figure 19 – Stress Results – Sheave Housing (Cleared values bellow 300MPa)

From figures of stress results for load case 2, its clear that same comments as for load
case are valid, only difference is in fact that stress results in load case 2 are even better than
in load case 1.

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3.5 Deformation Results

3.5.1 Load Case 1

Figure 20 – Deformation Results – Complete Assembly

Page 20 of 21
3.5.2 Load Case 2

Figure 21 – Deformation Results – Complete Assembly

4. Conclusion

From exposure listed above conclusion is that structural integrity of “tugger” sheave
will not be disrupted under loading conditions described I this report.

5. Appendix

Page 21 of 21