Scholars' Mine Doctoral Dissertations Student Theses and Dissertations Fall 2018 Computational dynamics and virtual dragline simulation for extended rope service life Muhammad Wardeh Follow this and additional works at: https://scholarsmine.mst.edu/doctoral_dissertations Part of the Engineering Mechanics Commons, and the Mining Engineering Commons Department: Mining and Nuclear Engineering Recommended Citation Wardeh, Muhammad, "Computational dynamics and virtual dragline simulation for extended rope service life" (2018). Doctoral Dissertations. 2732. https://scholarsmine.mst.edu/doctoral_dissertations/2732 This thesis is brought to you by Scholars' Mine, a service of the Missouri S&T Library and Learning Resources. This work is protected by U. S. Copyright Law. Unauthorized use including reproduction for redistribution requires the permission of the copyright holder. For more information, please contact [email protected]. COMPUTATIONAL DYNAMICS AND VIRTUAL DRAGLINE SIMULATION FOR EXTENDED ROPE SERVICE LIFE by MUHAMMAD WARDEH A DISSERTATION Presented to the Faculty of the Graduate School of the MISSOURI UNIVERSITY OF SCIENCE AND TECHNOLOGY In Partial Fulfillment of the Requirements for the Degree DOCTOR OF PHILOSOPHY in MINING ENGINEERING 2018 Approved by: Samuel Frimpong, Advisor Kwame Awuah-Offei, Co-advisor Grzegorz Galecki K . Chandrashekhara Elvan Akin 2018 MUHAMMAD ALI WARDEH All Rights Reserved iii ABSTRACT The dragline machinery is one of the largest equipment for stripping overburden materials in surface mining operations. Its effectiveness requires rigorous kinematic and dynamic analyses. Current dragline research studies are limited in computational dynamic modeling because they eliminate important structural components from the front-end assembly. Thus, the derived kinematic, dynamic and stress intensity models fail to capture the true response of the dragline under full operating cycle conditions. This research study advances a new and robust computational dynamic model of the dragline front-end assembly using Kane’s method. The model is a 3-DOF dynamic model that describes the spatial kinematics and dynamics of the dragline front-end assembly during digging and swinging. A virtual simulator, for a Marion 7800 dragline, is built and used for analyzing the mass and inertia properties of the front-end components. The models accurately predict the kinematics, dynamics and stress intensity profiles of the front-end assembly. The results showed that the maximum drag force is 1.375 MN, which is within the maximum allowable load of the machine. The maximum cutting resistance of 412.31 KN occurs 5 seconds into digging and the maximum hoist torque of 917. 87 KN occurs 10 seconds into swinging. Stress analyses are carried out on wire ropes using ANSYS Workbench under static and dynamic loading. The FEA results showed that significant stresses develop in the contact areas between the wires, with a maximum von Mises stress equivalent to 7800 MPa. This research study is a pioneering effort toward developing a comprehensive multibody dynamic model of the dragline machinery. The main novelty is incorporating the boom point-sheave, drag-chain and sliding effect of the bucket, excluded from previous research studies, to obtain computationally dynamic efficient models for load predictions. iv ACKNOWLEDGMENTS All praises are due to Allah (God), the almighty, for the strength and wisdom that I am blessed with to complete this research. I am very thankful to my research advisor, Dr. Samuel Frimpong, for his support, guidance, patience, and encouragements that he has provided to make this research possible. I feel blessed to have a caring advisor like him and great human being. I am deeply thankful to him for giving me the freedom to dig deeper. I am also grateful to my co-advisor, Dr. Kwame Awuah-Offei, for the ideas that he has shared during my research journey. I would like to thank my committee members: Dr. K. Chandrashekhara, Dr. Grzegorz Galecki, and Dr. Elvan Akin for their time and feedback. I am indebted to my loving wife, Lena Rashoud, who provided a tremendous support during this journey. She typed a large portion of the dissertation report and trusted in me. She has endured many days and nights alone during my PhD research study. I am thankful to her for being in my live. I am thankful to my friend, Salah Al Smairat, who provided a tremendous support. I greatly acknowledge the assistance of the staff members in the Department of Mining and Nuclear Engineering. I am also thankful to the Heavy Mining Machinery Research Group for their time and friendship. This research would not have been possible without the financial support of the Robert H. Quenon Endowment Fund and the funding provided by Missouri S&T for completing the PhD research. Finally, I am very grateful to my parents, Ali Wardeh and Dalal Wardeh, for their prayers, support and encouragements during the journey. I am also thankful to my siblings, especially my brother Oussama Wardeh, for their thoughts and support. v TABLE OF CONTENTS Page ABSTRACT ....................................................................................................................... iii ACKNOWLEDGMENTS ................................................................................................. iv LIST OF ILLUSTRATIONS ............................................................................................. ix LIST OF TABLES ........................................................................................................... xiii NOMENCLATURE ........................................................................................................ xiv SECTION 1. INTRODUCTION ...................................................................................................... 1 1.1. BACKGROUND OF THE PROBLEM.............................................................. 1 1.2. STATEMENT OF THE PROBLEM .................................................................. 5 1.3. RESEARCH SCOPE AND OBJECTIVES OF THE STUDY ........................... 8 1.4. RESEARCH METHODOLOGY........................................................................ 9 1.5. SIGNIFICANCE AND RESEARCH CONTRIBUTIONS .............................. 10 1.6. STRUCTURE OF DISSERTATION ............................................................... 11 2. LITERATURE SURVEY ........................................................................................ 13 2.1. DRAGLINE MACHINERY ............................................................................. 13 Operational Characteristics and Performance Monitoring. .................... 16 Dragline Simulation and Automatic Control.......................................... 23 2.2. EXCAVATION METHODOLOGY AND MODELLING TECHNIQUES .... 24 Kinematics and Dynamics Modeling of Excavators. ............................. 27 Kinematics and Dynamics Modeling of Dragline. ................................ 36 vi 2.3. DYNAMIC LOADS IN DRAGLINE ROPES ................................................. 38 Hoist Rope - Sheave Interactions. .......................................................... 42 Drag Rope-Formation Interactions ......................................................... 48 2.4. STRUCTURAL INTEGRITY OF FRONT-END ASSEMBLY ...................... 55 Finite Element Analysis of Ropes. ......................................................... 58 Fatigue Analysis of Ropes ...................................................................... 60 2.5. RATIONAL FOR PHD RESEARCH .............................................................. 63 2.6. SUMMARY ...................................................................................................... 66 3. COMPUTATIONAL DYNAMICS MODEL OF A DRAGLINE FRONT-END ASSEMBLY ............................................................................................................ 67 3.1. GEOMETRIC DESCRIPTION OF DRAGLINE MACHINERY ................... 68 3.2. KINEMATICS OF THE DRAGLINE FRONT-END ASSEMBLY................ 71 Kinematics Constraint Equations. .......................................................... 74 Nonholonomic System and its Partial Velocities ................................... 82 Linear and Angular Accelerations. ......................................................... 85 3.3. DYNAMICS OF THE DRAGLINE FRONT-END ASSEMBLY ................... 87 Inertia Torques of the Structural Components ....................................... 89 Kane’s Method ....................................................................................... 90 3.3.2.1 Generalized inertia forces ...........................................................90 3.3.2.2 Generalized active forces. ...........................................................93 3.3.2.3 Dynamics of the dragline bucket. ...............................................96 3.4. SUMMARY .................................................................................................... 105 4. NUMERICAL SOLUTION PROCEDURES AND VIRTUAL PROTOTYPE MODELING .......................................................................................................... 107 vii 4.1. NUMERICAL SOLUTION PROCEDURES ................................................. 108 Kinematics Solution Procedures .......................................................... 109 4.1.1.1 Initial condition search ..............................................................112 4.1.1.2 Singularity of closed front-end assembly. ................................119 4.1.1.3 Baumgarte’s