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An Investigation into the Failure of Belly Dump Trailers

An Investigation into the Failure of Belly Dump Trailers. Mr Peter Airey BE GradDipAdmin FIEAust CPEng RPEQ Managing Director - Airey Taylor Consulting Engineers & Scientists Chairman – Advanced Substructures Ltd. Dump Truck Arrangement.

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An Investigation into the Failure of Belly Dump Trailers

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  1. An Investigation into the Failure of Belly Dump Trailers Mr Peter Airey BE GradDipAdmin FIEAust CPEng RPEQ Managing Director - Airey Taylor Consulting Engineers & ScientistsChairman – Advanced Substructures Ltd

  2. Dump Truck Arrangement Product Mass = ~70,000kg/trailer = 211,000kg total Dump Truck Mass = 16,000kg Dolly Mass = 3,500kg

  3. Typical Failure

  4. Investigation Methodology Max. Horizontal Design Load = 320 kN Mass Flow, Squad Containers: Geometry Type C2

  5. Stress Modelling & Analysis SAP2000 Static and Dynamic Finite Element Analysis Quantify working stresses in trailer body Particular focus on welded arm connections

  6. Stress Modelling & Analysis Combination of principal stresses evaluated using “Von Mises” criterion:

  7. Stress Modelling & Analysis Figure 4 • Ed = 1.2G + 1.5Q (Fig. 4) • Stresses limited further at welded connections to prevent fatigue failureAS/NZS 4100-1998 – Cl. 11.5 & 11.6: • Detail Category 56 • Fatigue Stress = 90 Mpa (106 cycles) Maximum Von Mises Stress of 320MPa at arm connection and 460MPa at access hatch

  8. Conclusions Limiting fatigue stresses exceeded in multiple locations Problem locations determined via analysis correlated with areas of repeat failure Design-generated issue Mechanical design of such scale requires qualified structural design input

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