Finite Element Analysis for Structural Analysis of a Drum-Shaft Assembly in Bulk Material Handling Equipment

Resumo

This work aims to present a detailed structural investigation carried out through numerical simulations using the finite element method, applied to the drum of a metal extractor used in the handling of bulk granular materials. The main motivation for this study arises from the recurring observation of structural failures due to shaft fractures, which have been identified through predictive monitoring strategies and periodic visual inspections. The analyses indicate that these failures are caused by fatigue mechanisms associated with rotational bending, especially in regions with geometric transitions, and are worsened by compressive loads from fastening elements. To perform the structural analyses, a detailed three-dimensional model of the drumshaft assembly is developed, incorporating key components such as hubs, expansion rings, bearings, and fastening bolts. The computational simulations consider the actual operating conditions of the equipment, including the system’s self-weight, the tension transmitted by the belt, and the assembly torque applied to the expansion rings. The structural assessment reveals critical regions of stress concentration, with safety factors below the minimum recommended values for cyclic loading conditions. Based on the results, the shaft design is reformulated with specific geometric modifications and the replacement of the original material with a metal alloy of higher mechanical strength, aiming to mitigate fatigue effects. The results demonstrate the effectiveness of the finite element method as a tool for structural diagnosis and optimization, enabling the anticipation of failures, enhancement of the design, and increased operational reliability. This highlights the importance of accurate modeling and the consideration of real operating conditions in making technical decisions in industrial environments.