Finite Element Analysis of Trash Bin used for Metal Scrap

Disposal
R. J. Bhatt1, H. K. Raval2

1 2
Research Scholar, Professor,
Department of Mechanical Engineering, Department of Mechanical Engineering,
SVNIT, SVNIT,
Surat. Surat.
E-mail: ravi_bhatt9988@yahoo.co.in E-mail: hkr@med.svnit.ac.in

Abstract: As new market requirements have becoming more demanding through

introduction of new technologies for improvements in performance trends, these FEM
based software simulation has becoming more affordable & reliable as they reduces lead
time & cost. Scrap recycling is an essential part of any manufacturing enterprise. This
gives some amount of pay back in terms of revenue. Present study concentrates on the
Finite element analysis of trash bin with three different cases have been done (1) trash bin
at rest (2) lifting of trash bin at side supports & (3) lifting of trash bin with pad eyes/lifting
lugs. ANSYS, the commercially available finite element tool is used for the analysis.
Stresses developed & deformations have been obtained using FEA.

Index Terms: Trash Bin, Metal Scrap, Pad Eye, Simulation

1.0 INTRODUCTION

The trash bin is typically used for metal scrap collection/disposal. Many of the industries deals
with metals are using these kinds of bins. Trash bins are available with different sizes & shapes
readily in the market. The size of the trash bin & volume of the bin is varying from manufacturer to
manufacturer. The detailed drawing of trash bin is given in Fig. 1, was analysed using ANSYS.

Fig. 1 Manufacturing Drawing of Trash Bin without pad eye (courtesy by Noble Corporation)
The analysis is carried out in three cases are mentioned below.
(1) Trash Bin at rest: In this case the analysis has been carried out when the trash bin is at
rest position.
(2) Lifting of trash bin at side support: Here the trash bin is lifted from the side supports.
(3) Lifting of trash bin at pad eyes: In this case the given trash bin is lifted at pad eyes. The
drawing of pad eye and the location of each pad eye has been predefined. It has been
considered that the pad eyes were welded on the upper portion. The design for the pad
eye has also been verified.
Note: In each of the case mentioned above the trash bin is full with metal scrap.

2.0 LITERATURE REVIEW

There are number of research has been reported using finite element analysis. Bhatt and Kansara
(2012) done the static analysis of filter press using ANSYS to determine the von mises stresses &
deformation & it was confirmed by another FE tool AUTODESK/INVENTOR.
Chen & Zhu (2011) has done finite element analysis & optimization of design for dump trucks sub
frame using ANSYS & found that the deferent stresses are the result of fatigue cracks. This
problem has been resolved in optimization of the design & the intensity of the stresses has been
reduced.
Nam et al (2011) investigated the structural analysis of ITER Tokamak machine which includes
the cryostat & components contains therein. The sector sub-assembly tools descried in this paper
are main assembly tools to assemble vacuum vessel, thermal shield and toroidal filed coils into a
complete 40◦ sector. The 40◦ sector sub-assembly tools are composed of sector sub-assembly
tool, including radial beam, vacuum vessel supports and mid-plane brace tools. In this work the
strength & stability along with deflection has been analyzed using ANSYS.
Rust et al. (2003) analyzed thin walled structures using ANSYS. In this work they have been used
the models of keel airship cargo lifter, telescope crane & car roof for non linear limit load analysis.
3.0 FEA SIMULATION

3.1. Solid Modeling

Trash bin has been modeled in PRO-E software as SOLID MODEL, commercially available solid
modeling tool.

Fig. 2 CAD Model of Trash Bin without Pad Eye Fig. 3 CAD Model of Trash Bin with Pad Eye

3.2. FEA Simulation using ANSYS

 As already mentioned that the analysis has been carried out in three cases, those are explained
below. For all the three cases force is divided on the basis of volume of each compartment. The
left hand side compartment is biggest so it is subjected to load of 2.876 tons & remaining two
(middle & right) which are same in size are subjected to load of 1.811 ton each. So that the total
load on trash bin is 6.5 ton. The self weight of bin is also considered in the analysis. (Note: The
6.5 ton of load is predefined by manufacturer)

3.2.1 Trash Bin at rest

Here the application of forces has been defined in two different sets of boundary conditions. In
first set the forces are applied on the front, bottom & back plates as shown in Fig. 4 & in second
set forces are applied on front, bottom, back & side plates as shown in Fig. 5. Also fixed support
provided on the bottom surface of the bin.

TABLE 1 Mechanical Properties of Material used for Trash Bin Manufacturing

Material Type A-36 (Plates) ASTM 4140 (Round Bar)

Yield Tensile Strength (MPa) 250 415

Poission’s Ratio 0.26 0.29

Density (Kg/mm3) 7850 7850

Modulas of Elasticity (MPa) 2 x 105 2.05 x 105

Ultimate Tensile Strength (MPa) 400-550 655

Fig. 4 Boundary conditions for first set (First case) Fig. 5 Boundary conditions for second set (First Case)

3.2.2 Lifting of Trash Bin at Side Support

In this section the analysis has been carried out when the trash bin is supported on the four side
rods which are fitted on the side channels. Here also the two set of boundary conditions defined
same as the above section but the fix supports are provided at four side rods. Fig. 6 & Fig. 7 show
the two different sets of boundary conditions for this section.
Fig. 6 Boundary conditions for first set (Second Case) Fig. 7 Boundary conditions for second set (Second
Case)

3.2.3 Lifting of Trash Bin at Pad Eyes

In this case the trash bin is lifted with at the pad eyes the drawing (Fig. 8) & design verification for
standard pad eye is given below.

Fig. 8 Detailed drawing of pad eye

Material properties are same as A-36 & Total load = 6.5 tons + 1.5 tons = 8 tons = 78480 N

So, load on each pad eye (total four pad eyes on each bin) = 19620 N

Allowable shear stress [ =25 MPa

Allowable Tensile stress = 50 MPa

 Considering shear failure of pad eye,

  Considering tensile failure of pad eye,

 Considering crushing failure of pad eye,

 Welding strength calculation

Strength of fillet weld at sides of pad eye of 10 mm size
P1 = 0.707 * 10 * 76 * 25* 2 = 26666 N > [19620 N]

The two sets of boundary conditions have been considered according to previous sections & the
fixed supports have been defined at the pad eyes. Fig. 9 & Fig. 10 show the two sets of boundary
conditions.

Fig. 9 Boundary conditions for first set (Third Case) Fig. 10 Boundary conditions for second set (Third Case)

4.0 RESULTS & DISCUSSION

The von mises stress & maximum deformation for each case as well as each set of boundary
conditions are given below. Table 2 shows the total deformation & max. von mises stresses for
each case & each set of boundary conditions.
 Fig. 11 Total deformation (mm) & von mises stress (MPa) for first case & first set of boundary conditions

Fig. 12 Total deformation (mm) & von mises stress (MPa) for second case & first set of boundary conditions

Fig. 13 Total deformation (mm) & von mises stress (MPa) for third case & first set of boundary conditions

Similarly total deformation & von mises stresses have been obtained for second set of boundary condition for
three cases of loading conditions.
 TABLE 2 Total Deformation & Von Mises stresses for each case & each B.C.

Max. Von
Total
Mises
Case No. Case Set of B.C. Deformation
Stresses
(mm)
(MPa)

Trash Bin at I 0.650 16.765

I
rest II 0.265 5.628

Lifting of I 1.4656 51.56

II Trash Bin at
Side Support II 0.813 53.542

Lifting of I 1.46 95.68

III Trash Bin at
Pad Eyes II 0.54 99.99

5.0 CONCLUSION

Here an attempt is made to determine max. Stress and deflection using static analysis
approach through FEA simulation by ANSYS. Based on this study following conclusions have
been drawn.
 The total deformation is reduced in each case for second set of boundary conditions
e.g. forces are applied on front, bottom, back & side plates.
 Maximum Von Mises stresses & total deformations are very small compared to the
other dimensions of trash bin in each of the three cases & for each set of boundary
conditions.
 The design of pad eye is safe for lifting trash bin with 6.5 ton of load.

 The trash bin is safe for 6.5 ton of loading. Also lifting can be facilitate by any means
e.g. by side support or by pad eyes.
 This will help industry to optimize the product. That ultimately reduces cost.

6.0 REFERENCES

1. Bhatt R. J., Kansara K., 2012, “Static Analysis of Filter Press using ANSYS”, Recent Advances in
Manufacturing, Proceedings, SVNIT, Surat
2. Chen Y., Zhu F., 2011, “The Finite Element Analysis and The Optimization Design of the Yj3128-type Dump
Truck’s Sub-Frames Based on ANSYS”, Procedia Earth & Planetary Science, pp. 133-138
3. Nam K. O., Park H. K., Kim D. J., Ahn H. J., Lee J. H., Kim K. K., Im K., Shaw R., 2011, “Structural analysis of
ITER sub-assembly tools”, Journal of Fusion Engineering & Design, pp. 1805-1808.
4. Rust W., Schweizerhof K., 2003, “Finite element limit load analysis of thin-walled structures by ANSYS
(implicit), LS-DYNA (explicit) and in combination”, Journal of Thinned Walled Structures, pp. 227-244.
5. Mehta N. K., 1999, “Tool Design Data book”, Third Edition, pp.18-78.