FEA stress analysis with strain gauging to verify results
A run of mine (ROM) bin hopper was equipped with strain gauges, and the results were compared to a coupled DEM-FEA simulation conducted in LS-Dyna. The ROM Hopper features a main shell section, a grizzly at the top inlet, and a conveyor belt, and it is loaded with bulk material using a front-end loader. The purpose of the project was to calculate stresses in the hopper structure resulting from loading and emptying of the bin.
Nine strain gauges were attached to the lower section of the bin. The FEA-DEM model incorporated the front-end loader's loading process to replicate the test conditions. However, the primary difference was a significant reduction in the time between loads to accelerate the simulation.
OBSERVATIONS & KEY OUTCOMES
- The stress magnitudes from the FE model closely matched the strain gauge stress results.
- Strain gauge 4 (SG4) recorded the highest stress, exceeding 100 MPa before the conveyor belt was activated.
- The FE model exhibited dynamic effects at the start of the simulation, which were not present in the physical test. This discrepancy is likely due to the absence of liner plates in the FE model, causing all impacts to be directly absorbed by the outer shell.
- Once some material was present in the model, the dynamic effects from loading largely subsided, and stress increased in a more controlled manner, aligning with test observations.
- A significant dynamic spike occurred when the conveyor belt was started, an effect observed in both the simulation and the test.
- The shock impact has a significantly greater effect on the deformation and stress in the bin supports compared to the actual bin loading.
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