Prepared By: Abdullah Amin Date:13th Nov, 2024

FINITE ELEMENT ANALYSIS OF LIFTING LUG

Introduction
The purpose of this report is to present the finite element analysis (FEA) conducted on the lifting lugs of a
chemical injection skid platform. In this analysis, horizontal configuration of lug is simulated, as these
lugs provided more clearance for slings from skid equipment as compared to the vertical lugs. The initial
loads were calculated from STAAD Pro and were applied at the top inner surface of lug. Both linear and
non-linear analysis were performed to evaluate the stress distribution, of the lug.

The design of lug was guided by ASME standards, considering the calculated dimensions and thicknesses
with an initial design factor of 2. In the FEA, particular attention is paid to high-stress regions,
specifically around the inner surface of the lug hole, where preliminary results indicated a concentration
of stresses. The main concern was regarding the twisting of pin and application of severe load around the
hole edges. Various possible loadings were applied to simulate such a scenario and study stresses.

Moreover, lateral bending was also considered around the minor axis of the lug. The stresses produced
were typically high around the beam-side top surface of the lug.

This report documents the analysis methodology, material properties, boundary conditions, and results of
the FEA, providing recommendations based on observed stress concentrations and overall lug
performance under the applied load conditions.

Methodology
Modeling
The first step was to create a lifting lug model, which was created on Autodesk using the drawings of the
lug. The thickness of the lug is taken to be 20mm.

Figure 1-Dimension drawing of lifting lug from Autodesk

Prepared By: Abdullah Amin Date:13th Nov, 2024

Meshing
The next step is to mesh the model, here consideration was given to regions around the hole. The mesh
was made finer until further reduction did not show any considerably large changes in results. The mesh
is hex-dominant and elements are 3D solid elements with 24 DOF per element.

Figure 2-Meshing of lug on ANSYS

Boundary Conditions
The face of the lug facing the I-beam was fixed and was considered as a fixed support. In reality, there
will be no fixed support in the whole platform which will allow the whole platform to deform and take
stress, but for the sake of our local analysis at lug we are considering a fixed support (this assumption will
elevate the stresses in comparison to reality.)

Figure 3-Boundary conditions applied for analysis

Prepared By: Abdullah Amin Date:13th Nov, 2024

Load Application
The third step is the load application around the hole. Initially a load of 42.214 kN at angle of 65 degrees
to horizontal axis of lug was applied. The load was resolved into 37.79kN in vertically upward direction
while 17kN in the lateral direction of the lug.

Figure 4- Direction of load application on lug

Now the main concern of analysis is regarding the area at which the load will act. For this sake various
load cases were analyzed by applying load at different areas of the hole and structural stability was
studied.

Load Case 1
In the first load case the load was applied at around 700mm^2 of the top inner surface area of the hole.
This analysis is based on the assumptions from ASME BTH calculations and assumes that the pin will not
twist inside the hole and all load is directly applied to the upper inner surface of the hole. The area in this
case is taken from the BTH-1 calculation for bearing strength (Ap=700mm^2)

Figure 5-Nodes at which load is applied for Case 1

Prepared By: Abdullah Amin Date:13th Nov, 2024

Load Case 2
The second load case is based on the assumption that due to load in Z-direction, pin will move a little in
that direction and instead of twisting either the pin head or nut attached to the other side will apply force
on the side of the lug in the z-direction.

In this case vertical load will be taken by the inner surface of the lug will take the horizontal load that will
act on the side of the lug towards the z-direction.

Figure 6-Nodes at which load is applied for Case 2

This load case is supported by an actual lifting scenario as shown in the following picture;

Load being transferred to

the side of the lug as well

Figure 7- Actual Load transfer scenario

Prepared By: Abdullah Amin Date:13th Nov, 2024

This loading situation clearly shows load transfer from shackle to the side of lug.

Load Case 3
The third load case assumes that the pin will twist, and the load will predominantly act around the edges
of the hole. At the upper edge of the hole the load will act in the upward direction.

Figure 8-Nodes at which load is applied for Case 3

The lower edge of the hole will bear a negative z directional force and the upper edge will be bear a
positive lateral force. While the vertical load will only be taken by upper edge

Figure 9-Nodes in Case 3

To apply the load on the edge the elements connected to edge are selected and load is applied on their
nodes.
Prepared By: Abdullah Amin Date:13th Nov, 2024

Analysis
Firstly, linear static structural analysis was performed assuming the material properties of S275 JR with
elastic modulus of 210GPa.

Most linear analysis yielded very high stress concentrations around the hole exceeding 500MPa. This is
because the linear analysis assumes a linear stress strain relation even after yield point, moreover it does
not considers the changes in stiffness that occur due to large deflections that occur when a member
displaces even in elastic region. Therefore, bi-linear material was assumed with a tangent modulus of
2000.

Figure 10-Bilinear Material Model

Large deflections were considered, and a non-linear analysis was performed. The load was divided into 10
sub steps and the maximum sub steps were set to 100 to obtain convergence. The results of non-linear
analysis were judged based on plastic strain.

Figure 11- Non-linear setting on Ansys

Another important factor to consider is that the maximum stress is calculated according to Von misses
theory for both linear and non-linear analysis.
Prepared By: Abdullah Amin Date:13th Nov, 2024

Results
Load Case 1
This load case assume the application of load to around 700mm2 of area on the top inner surface of lug.

Linear Analysis Results

These linear analyses were performed with the original load of 41.214kN.

Figure 12-Linear analysis result for load case 1

The linear analysis gives around 343 MPa at top corner of lug facing I beam and around 240 MPa around
the hole edges.

Discussion
The high stress at the top beam side of lug seems to be critical, but it must be noted that the reason for
such high stress value is the fixed boundary, which in reality will not be the case, and stresses will be
transferred to the whole platform which will displace as a single body. Hence the stresses at these regions
cannot be considered critical under this analysis.

The high local stresses around hole edges are also accurate, but these local stresses will be developed at
regions immediately around sharp hole corners. Since linear analysis does not consider any changes in
stiffness during loading, the high stress of 240 MPa may also diminish in non-linear results.
Prepared By: Abdullah Amin Date:13th Nov, 2024

Load case 2
The second load case includes applying side load on lug in z direction and vertical load on inner surface
of the hole.

Linear Results
Firstly the linear analysis was performed and the results are as follows:

Figure 13-Linear analysis results load case 2

There is around 360 MPa of stress that develops on lug side facing beam and the maximum stress value is
at hole edge 760MPa.

Figure 14-Magnified imaged of stresses aroung lug hole

Discussion
The linear analysis is giving excessive stresses that will not be actually taken by the structure in reality.
Anyhow the analysis shows two areas of concern, lug top side towards beam and hole edge.

The very high stresses developing around hole edge will be relieved as the model yields a bit but this
phenomenon can not be captured by linear analysis. Therefore, non-linear analysis is considered to further
analyze the structure.
Prepared By: Abdullah Amin Date:13th Nov, 2024

Non-Linear Results
Considering large deformations and bi-linear material nature the results are as follows:

Figure 15-Non-linear Results for load case 2

The max stress is at top edge of 321 MPa again while max stress at the side of hole is 245 MPa.

Figure 16-Maginifed image of stresses around lug hole

Discussion
Non-linear analysis clearly shows that the stresses around edge hole in this case do not exceed maximum
yield limit. This is because the initial load application results in some elastic yielding that will allow
stresses to be distributed better. Although the stresses around lug side towards beam are high in this case
as well. However, these cannot be given much significance as explained in load case 1.
Prepared By: Abdullah Amin Date:13th Nov, 2024

Load Case 3
In this case we assume the pin twists due to force in z-direction and a negative z force is applied at lug
hole bottom edge. While the vertical load will be carried by the upper edge of the lug.

Linear Results
The results due to linear static structural analysis are shown as follows:

Figure 17-Linear analysis Load Case 3

Figure 18-Stress concentration around hole edge

A maximum of 645 MPa stress is developed in the hole edges and the stress at face is almost none. The
high local stresses in this case will be better explained by non-linear analysis.
Prepared By: Abdullah Amin Date:13th Nov, 2024

Non-Linear Analysis
The results of non-linear analysis of lifting lug with third load case are as follows:

Figure 19-Non-linear analysis load case 3 Figure 20-Stress around lug hole

It is clear that a maximum load of 292MPa will be developed at the inner side of the shell while a load of
only 200 MPa is developed at lug face towards I-beam.

Since yielding has happened, we must take into account the amount of plastic strain.

Figure 21-Plastic Strain in Lug

There is a plastic strain of about 0.5% that will be produced at the top edge of hole.

Discussion
Although the non-linear analysis shows plastic yielding, the plastic strain developed is 0.5% which is not
very high. Anyhow, slight improvements in geometry can be made to further reduce stress, for example
introducing a fillet around the edge hole will ensure a larger surface area for load.
Prepared By: Abdullah Amin Date:13th Nov, 2024

Summary
The results of all analyses performed are given as follows:

Linear Analysis Non-Linear Analysis

Stress (Hole) Stress (Beam- Stress (Hole) Stress (Beam- Plastic Strain
MPa Side) MPa MPa Side) MPa
Load Case 1 240 343 --- --- ---

Load Case 2 760 360 245 321

Load Case 3 645 0.004 292 200 0.5%

Conclusion
From these analysis we can conclude that the lug will be able to take the load without failing although
there might be some plastic deformations around the edge of the hole. Extra padding can be added around
the hole to avoid this situation.