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Notre Dame University (Louaize)

Faculty of Engineering
Department of Mechanical Engineering

MEN 437
Mechanical Engineering Design
Spring 2025

Movable Cantilever Beam Lifter

Prepared by:

Joana Jabbour 20202879

Rodolph Aazar 20193344

Farid Ghorayeb 20171877

Submitted to:

Dr. George Chalita

May 2025
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Abstract
The study aims at the mechanical design and analysis of a portable cantilever arm lifter with
particular emphasis on the arm structure, joints, and base components that are frequently subjected
to severe loading and stability demands. The project aims at optimizing the said components for
improved performance, durability, and safety using MATLAB programming, SolidWorks
simulation, and theoretical calculation. The outcomes are the identification of [high-strength steel]
as the arm material, the joint dimensions optimized for a yielding safety factor, and a base design
for the stability of the system at maximum loading. The integration of rigorous material selection,
advanced simulation, and analytical methods ensures flawless operation and adaptability in
managing various lifting operations in industrial/laboratory/other settings.
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Contents
Abstract ......................................................................................................................................................... 2
Chapter 1: Introduction ................................................................................................................................. 5
Chapter 2: Literature Review ........................................................................................................................ 6
2.1 Cantilever Arm Design and Loading .................................................................................................... 6
2.2 Performance of Joint and Pivot Mechanism ....................................................................................... 7
2.4 Material Selection and Fatigue Considerations .................................................................................. 8
2.5 Optimization of Design in Contemporary Systems ............................................................................. 8
Chapter 3: Objectives .................................................................................................................................... 9
Chapter 4: Design and Calculations ............................................................................................................ 10
1-Cantilever Arm: ................................................................................................................................... 10
Design Calculations: ............................................................................................................................ 10
Endurance limit ................................................................................................................................. 12
SolidWorks Simulation ........................................................................................................................ 15
2- Bolts .................................................................................................................................................... 17
MATLAB Analysis ............................................................................................................................ 18
3- Spring .................................................................................................................................................. 20
MATLAB: ............................................................................................................................................. 23
Results Summary:.................................................................................................................................... 26
Chapter 5: Conclusion................................................................................................................................. 27
References ................................................................................................................................................... 28
Appendix A .................................................................................................................................................. 29
Appendix B .................................................................................................................................................. 31
Appendix C .................................................................................................................................................. 33
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Table of Figures
Figure 1 Cantilever Arm Lifter........................................................................................................................ 6
Figure 2 Front view of the mechanism. ........................................................................................................ 7
Figure 3 2D Sketch of the components. ........................................................................................................ 7
Figure 4 Free body diagram of the cantilever. ............................................................................................ 11
Figure 5: Surface condition modification factor. ......................................................................................... 12
Figure 6: Equivalent diameter for different cross sections. ........................................................................ 13
Figure 7: Size modification factor equations ............................................................................................... 13
Figure 8 Beam analysis MATLAB. ................................................................................................................ 15
Figure 9 Beam design with fixation and load location. ............................................................................... 15
Figure 10 Deflection of the beam. .............................................................................................................. 16
Figure 11 Stress analysis on the beam. ....................................................................................................... 16
Figure 12 Bolt Configuration. ...................................................................................................................... 17
Figure 13 Bolt data. ..................................................................................................................................... 19
Figure 14 MATLAB simulation. .................................................................................................................... 19
Figure 15 Spring Configuration. .................................................................................................................. 20
Figure 16 Table of design for aswound springs for diameters 6mm till 12mm. .......................................... 23
Figure 17 Table of design for aswound springs for diameters 13mm till 19mm. ........................................ 24
Figure 18Table of design for set removed springs for diameters 6mm till 12mm. ..................................... 24
Figure 19 Table of design for set removed springs for diameters 13mm till 19mm. .................................. 24
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Chapter 1: Introduction
Mobile cantilever arm lifters are very handy equipment in many laboratory and industrial
environments. Their ability to lift, position, and transfer loads efficiently makes them immensely
helpful in improving workflow, reducing manual handling, and enhancing safety. However, the
engineering design of such systems faces many challenges. The arm must withstand high bending
moments and shear stresses while providing stability and mobility. Joints and pivots are subjected
to repeated loading, leading to wear or failure if not appropriately designed. The mobile base must
withstand dynamic loads during lifting and transportation, with no tipping or instability. The
project deals with the mechanical design, material, and structural analysis of a movable cantilever
arm lifter having a capacity of lifting and transporting loads of up to 300 kg safely. Special attention
is given to the arm geometry optimization, joint and base design configuration for better
performance and safety. A combination of theoretical calculations, finite element analysis (through
SolidWorks), and MATLAB-based calculations is utilized in stress, displacement, and factor of
safety predictions under expected operating conditions. The application of computational and
analytical tools to ensures the ultimate design meets all performance and safety requirements. By
addressing every design consideration in an orderly fashion, this project aims to devise a robust
and efficient lifting device suitable for warehouse applications, assembly lines, laboratory settings,
etc.…. The outcome and methodology can also inform future upgrades and refinements for similar
lifting mechanisms.
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Chapter 2: Literature Review

Movable cantilever arm lifting machines are used frequently in industrial, mechanical, and
maintenance contexts to allow the repositioning and positioning of heavy or cumbersome loads.
The machines have the advantage of reach and height without the requirement for a full crane
system. However, the design of such systems involves a careful balance between safety, weight,
strength, and mobility.

Figure 1 Cantilever Arm Lifter.

2.1 Cantilever Arm Design and Loading

Cantilever arms are structural elements with one fixed end and one free end, thus they are highly
sensitive to bending moment and shear force. In structural mechanics, the limiting bending stress
generally occurs at the fixed end, which must be strengthened with utmost care to avoid fatigue
crack and permanent deformation. Studies by Zhou et al. (2019) have established that arm
thickness, arm length, and arm cross-section geometry are crucial factors in controlling deflection
and stress concentration.
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Figure 2 Front view of the mechanism.

2.2 Performance of Joint and Pivot Mechanism

The pivot or hinge joints at the tip of the cantilever arms are essential to facilitate movement under
dynamic loading. The cyclic rotation and repeated stresses lead to wear out of these joints.
Incorrect sizing or lubrication may lead to premature deterioration. Simulation of cyclic load pivot
joints in a study by Martínez & Lee (2020) highlighted that surface fatigue and contact pressure
are important factors leading to joint failure.

Figure 3 2D Sketch of the components.

2.3 Risk of Tipping and Stability of Mobile Bases

As extended and loaded, the cantilever arm tips the center of gravity of the system. Unless
counterbalanced, this results in tipping, especially of mobile systems. Wheelbase width,
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counterweight location, and load distribution are all important to achieve static and dynamic
stability. A Singh et al. (2021) study on handheld lifting devices indicated that stability is optimally
achieved when the arm reach is limited to within 70% of the base width.

2.4 Material Selection and Fatigue Considerations

Material choice strongly influences the durability and performance of the arm lifter. Common
choices are aluminum alloys and high-strength low-alloy steels (e.g., AISI 4340, normalize 4340
steel), a compromise between weight and strength. Manufacturability, corrosion protection, and
resistance to fatigue are important selection considerations. Johnson & El-Rayes (2017)
emphasized that post-weld heat treatment and surface finishing improve fatigue life significantly
in welded steel arms.

2.5 Optimization of Design in Contemporary Systems

Modern engineering design employs computational packages like Finite Element Analysis (FEA)
and optimization techniques to minimize lifter designs. With simulation, the stress concentration
regions can be found, and the design parameters like arm cross-sectional area, bolt diameter, and
support frame rigidity can be optimized before actual manufacturing. Tanaka et al. (2022) used
SolidWorks and ANSYS to minimize deflection in a lifting arm, improving safety factor by 28%
without increasing the cost of the material.
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Chapter 3: Objectives
The objective of this project is to design a movable cantilever arm lifter with enhanced structural
integrity, operational safety, and reliability by addressing the failure modes of key components,
including the arm structure, lifting mechanism, and pivot assembly. Specifically, the goals are:

1. Enhanced Load-Bearing Capacity

o Optimize the cantilever arm and support column design to withstand both static and
dynamic loads during lifting operations, minimizing deflection, fatigue, and risk of
structural failure under various loading scenarios.
2. Improved Lifting Mechanism Reliability
o Redesign the lifting mechanism (such as winch, hoist, or pulley system) to resist
failure under combined operational loads, ensuring smooth, safe, and reliable lifting
through careful material selection and refined component geometry.
3. Increased Pivot and Joint Durability
o Develop more durable pivot and joint assemblies by mitigating stress
concentrations at critical connection points, exploring advanced materials or
treatments, and improving lubrication or bearing solutions to extend service life
and reduce maintenance needs.

To reach these goals, a combination of computational and practical tools will be utilized:

 Calculations to determine forces, moments, stresses, and fatigue life of key components
based on engineering principles and loading conditions.
 MATLAB Simulations for advanced numerical analyses, such as dynamic load response
and system stability modeling.
 SolidWorks for 3D modeling and analysis, allowing detailed visualization and finite
element stress simulation of each component.

The project will culminate in creating detailed designs, performance simulations, and optimization
recommendations to ensure a robust, safe, and reliable movable cantilever arm lifter suitable for
industrial applications.
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Chapter 4: Design and Calculations

1-Cantilever Arm:

The arm is modeled as a rectangular cantilever beam supporting a vertical point load of 8000 N
at its free end. The selected dimensions of the arm are based on deflection limits, stress criteria,
and manufacturability. The final cross-sectional dimensions were chosen to balance stiffness and
weight:

Table 1 Different design parameters.

Width (b) Height (h) Standard Source Comments

40 mm 100 mm ISO 657-1 / EN 10058 Standard flat bar
50 mm 100 mm Common RHS or solid
60 mm 120 mm ISO / EN Flat bar Matches your strength needs
75 mm 125 mm EN 10058 Overdesigned, heavy
100 mm 150 mm ISO 657 Very heavy-duty, difficult to machine

 Width (b): 60 mm
 Height (h): 120 mm
 Length (L): 1.2 m
 Material: Normalized 4340 steel
 Yield Strength (Sy): 862 MPa
 Ultimate Strength (Sut): 1279 MPa

The type of material used for the design is Normalized 4340 Steel.

Design Calculations:

In this section we will go through the calculations needed to design the fork in order to resist
fatigue failure and yielding.
A free body diagram was drawn to analyze the forces acting on the beam carrying the load.
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Figure 4 Free body diagram of the cantilever.

The load is taken as concentrated force acting at the end of the beam. Based on that assumption,
the force needed by the fork to hold the object is simply calculated using Newton’s First Law:
∑ 𝐹𝑦 = 0 we get 𝑅 − 𝑊 = 0
𝑚
The force required to hold the load is equal to the weight W, where 𝑊 = 𝑀𝑎𝑠𝑠 (𝐾𝑔) × 10 (𝑠2 ).
𝐹 = 8000 𝑁.
Consider a fluctuating force cycle to simulate the fatigue stresses on the fork.
A full cycle of loading will be considered where 𝐹𝑚𝑖𝑛 = 0 and 𝐹𝑚𝑎𝑥 = 8000 N. Failure happens
at the most critical point, where the stresses are highest. In this case, the stresses are highest at the
beginning of the cantilever arm. It is the farthest point from the force, so it has the highest moment.
In the X-direction:
∑ 𝐹𝑋 = 0
𝑁=0

In the Y-direction:
∑ 𝐹𝑦 = 0

𝑅 − 8000 = 0
𝑅 = 8000 𝑁

Summing moments:

∑ 𝑀𝑍 = 0

M − 8000 × (1.2) = 0
𝑀𝑍 = 9600 𝑁. 𝑚
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|𝐹𝑚𝑎𝑥 −𝐹𝑚𝑖𝑛 | 8000

Alternating force: 𝐹𝑎 = = = 4000𝑁
2 2
|𝐹𝑚𝑎𝑥 +𝐹𝑚𝑖𝑛 | 8000
Mean force: 𝐹𝑚 = = = 4000𝑁
2 2

There are no forces in the axial direction so the alternating and mean axial stress are considered
to be zero.
𝑁𝑎 𝑁𝑚
𝜎𝑎,𝑎𝑥𝑖𝑎𝑙 = = 𝜎𝑚,𝑎𝑥𝑖𝑎𝑙 = =0
𝐴 𝐴

Regarding the bending stresses:

0.12
𝑀𝑎 ×𝑐 9600×
Alternating bending stress: 𝜎𝑎,𝑏𝑒𝑛𝑑𝑖𝑛𝑔 = = 2
0.06×0.123
= 66.67 𝑀𝑃𝑎
𝐼
12

0.12
𝑀𝑚 ×𝑐 9600×
Mean bending stress: 𝜎𝑚,𝑏𝑒𝑛𝑑𝑖𝑛𝑔 = = 2
0.06×0.123
= 66.67 𝑀𝑃𝑎
𝐼
12

Endurance limit
To calculate the factors of safety, the endurance limit must be found first. Since the endurance limit
of a mechanical structure does not match the values of that obtained in a laboratory because of
surface conditions, size, temperature, and other aspects, finding the endurance limit by applying
the Marin equation. The same material (4340 steel) was tested on by extensive statistical analysis,
where the Marin equation was found to have 85% correlation when multiplying the factors while
the additive form had 40% correlation.
To do so: 𝑆𝑒 = 𝐾𝑎 𝐾𝑏 𝐾𝑐 𝐾𝑑 𝐾𝑒 𝐾𝑓 𝑆′𝑒

Where the factors are explained and found below:

1) Surface condition modification factor 𝑲𝒂 :

Figure 5: Surface condition modification factor.

Using the table above to get the factor a and the exponent b, we can calculate 𝐾𝑎 using the
𝑏
following equation 𝐾𝑎 = 𝑎 × 𝑆𝑢𝑡
In our case the surface finish is machined, using the data from figure 7 above, we can get a =
4.51 MPa and exponent b = -0.265, and 𝑆𝑢𝑡 = 1278.97𝑀𝑃𝑎.We can calculate:
𝑏
𝐾𝑎 = 𝑎 × 𝑆𝑢𝑡 = 4.51 × 1279−0.265 = 0.677
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2) Size modification factor 𝑲𝒃 :

Since we have a non-circular and non-rotating bar, we have to find the equivalent diameter to
calculate 𝐾𝑏 .

Figure 6: Equivalent diameter for different cross sections.

For a rectangular cross-section the equivalent diameter can be calculated using the equation:

𝑑𝑒 = 0.808√ℎ𝑏 = 0.808 × √0.12 × 0.06 = 68.56 𝑚𝑚

Figure 7: Size modification factor equations

For 51𝑚𝑚 < 𝑑𝑒 = 68.56𝑚𝑚 < 254𝑚𝑚, we use the equation: 𝑘𝑏 = 1.51𝑑𝑒−0.157 = 1.51 ×
68.56−1.57 = 0.777 .
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3) Load modification factor 𝑲𝒄 :

Since here we have bending only, we will take 𝐾𝑐 = 1

The remaining factors will be taken equal to unity, so 𝐾𝑑 = 𝐾𝑒 = 𝐾𝑓 = 1

𝑆′𝑒 can be calculated using the equation 𝑆′𝑒 = 0.5 × 𝑆𝑢𝑡 = 0.5 × 1279 = 644.616𝑀𝑃𝑎
𝑆𝑒 = 0.677 × 0.7535 × 1 × 1 × 1 × 1 × 644.616 = 339𝑀𝑃𝑎

We can now apply the Goodman fatigue criteria to find the fatigue safety factor.
𝜎𝑎 𝜎𝑚 1
+ =
𝑆𝑒 𝑆𝑢𝑡 𝑛𝑓

Substituting the values calculated above we find 𝑛𝑓 = 6.46

𝑆𝑦
Now calculating the yielding factor of safety: 𝜎𝑎 + 𝜎𝑚 = 𝑛𝑦

We can find 𝑛𝑦 = 4.02

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Figure 8 Beam analysis MATLAB.

SolidWorks Simulation

Figure 9: Beam design with fixation and load location.

As seen in Figure 9, the green arrows indicate the end of the beam, which is fixed. The purple
arrow shows the load on the end of the beam. The load acting on this surface resulted in the
following:
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Figure 10 Deflection of the beam.

Figure 11 Stress analysis on the beam.

Each of the figures 10 and 11, represent the deflection and stress concentration respectively. The
vertical axis color-bar shows the values of each parameter involved based on the contour color
shown on the cantilever arm.
This can confirm the highest stress location being at the beginning of the beam. The deflection also
correctly simulates that the farther away from the fixed point, the more deflection is present on the
beam.
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2- Bolts

Figure 12 Bolt Configuration.

To get the primary shear force on each bolt, we use the equation
𝑉 8000
𝐹′ = = = 2000𝑁 ⬇
2 4
Now to calculate the secondary shear force we need to find the moment first.
𝑀 = 8000 × 1.2 = 9600𝑁
Now the secondary shear can be calculated using the equation:
𝑀𝑟 9196.875 × 0.2
𝐹 ′′ = = = 24000𝑁
𝑟2 + 𝑟2 2
+𝑟 +𝑟 2 0.2 + 0.22 + 0.22 + 0.22
2

The resultant force 𝐹𝑟 can be calculated using:

𝐹𝑟 = √𝐹 ′2 + 𝐹 ′′2 = √20002 + 240002 = 24083.18𝑁

The orientation θ can be calculated using the equation:
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−1
𝐹′ 2000
θ = tan ( ′′ ) = tan−1 ( ) = 4.76˚
𝐹 24000

The shear stress in the bolt can be calculated using the equation 𝜏 =, where 𝐴𝑟 can be found from
table 8-1 coarse pitch M20x2.5.
𝐹𝑅 24083.18
𝜏= = = 107.03𝑀𝑃𝑎
𝐴𝑟 225
𝐹
The bearing stress can be calculated using the equation 𝜎𝑏𝑒𝑎𝑟𝑖𝑛𝑔 = − 𝐴𝑅
𝑏

where 𝐴𝑏 = 𝑡 × 𝑑 = 0.01 × 20 = 200 𝑚𝑚2.

(t is the thickness of the fork and d the diameter of the bolt).
𝐹𝑅 24083.18
𝜎𝑏𝑒𝑎𝑟𝑖𝑛𝑔 = − =− = −120.41𝑀𝑃𝑎
𝐴𝑏 1270
From table 8-11 we can get 𝑆𝑝 = 830𝑀𝑃𝑎 for M20x2.5 class 10.9. Now we can calculate the
𝑆𝑝
proof factor of safety 𝑛𝑝 = 𝝈′

Where 𝜎 ′ = √3𝜏 2 = √3 × 1072 = 185.32𝑀𝑃𝑎

𝑆𝑝 830
𝑛𝑝 = ′
= = 4.47
𝝈 185.32
The final dimensions of the bolt:
M20x2.5 class 10.9
Grip length 𝑙𝑔 = 𝑡𝑝𝑙𝑎𝑡𝑒 + 𝑡𝑐𝑎𝑟𝑟𝑖𝑎𝑔𝑒 + 2 × 𝑡𝑤𝑎𝑠ℎ𝑒𝑟 = 30 + 60 + 2 × 2.3 = 94.6 𝑚𝑚

We assumed a plate thickness of 20mm and 2.3mm washer thickness from table A-33.
A hexagonal nut of height 𝐻𝑛𝑢𝑡 = 18 𝑚𝑚, which was taken from Table A-31 for an M20 bolt, is
added to the grip length to get the minimum length of the bolt.
𝐿 = 𝑙𝑔 + 𝐻𝑛𝑢𝑡 + 2𝑝 = 94.6 + 18 + 5 = 117.6𝑚𝑚

According to Table A-17, the standard size closest to and greater than 117.6 mm is 𝐿 = 120 𝑚𝑚.
The unthreaded length of the bolt 𝑙𝑑 = 𝐿 − 𝐿𝑇 where 𝐿𝑇 = 2 × 𝑑 + 6 = 2 × 20 + 6 = 46𝑚𝑚
𝑙𝑑 = 𝐿 − 𝐿𝑇 = 120 − 46 = 74𝑚𝑚
The threaded length of the bolt 𝑙𝑡 = 𝑙𝑔 − 𝑙𝑑 = 94.6 − 74 = 20.6 𝑚𝑚

MATLAB Analysis
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Figure 13 Bolt data.

Figure 14 MATLAB simulation.

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3- Spring

Figure 15 Spring Configuration.

𝐹𝑚𝑖𝑛 = 16 × 10 = 16000𝑁
𝐹𝑚𝑎𝑥 = 16000 + 8000 = 24000𝑁

The study is done on 1 spring since all have the same analysis. Hence, the force acting on 1
spring is the above minimum and maximum forces divided by 2.

16000
𝐹1,𝑚𝑖𝑛 = = 8000𝑁
2
24000
𝐹1,𝑚𝑎𝑥 = = 12000𝑁
2

Using table 10-4 & 10-5 Chrome-Silicon wire is chosen since it has high tensile stress and is
mostly used for forklift coil springs.

Design assumptions:

Free, as-wounded or set removed

End: Squared and ground
Material: Chrome-silicon wire
ASTM No.: A401
Exponent m: 0.108
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Diameter: mm
A: 1974 [Link]
Relative cost of wire: 4.0
Robust linearity: ζ = 0.15
E = 203.4 GPa
G = 77.2 GPa

Similar to the analysis on the load, mean and alternating forces are taken into consideration:

𝐹1,𝑚𝑎𝑥 + 𝐹1,𝑚𝑖𝑛 12000 + 8000

𝐹𝑚 = = = 10000𝑁
2 2
𝐹1,𝑚𝑎𝑥 − 𝐹1,𝑚𝑖𝑛 12000 − 8000
𝐹𝑎 = = = 2000𝑁
2 2

Design constraints:

4 ≤ C ≤ 12
3 ≤ 𝑁𝑎 ≤ 15
𝜁 ≥ 0.15
𝑛𝑠 ≥ 1.2

The following equations will be used in the spring design to choose a suitable spring:

For set removed springs:

𝐴
𝑆𝑢𝑡 =
𝑑𝑚
𝑆𝑠𝑦 = 0.65 × 𝑆𝑢𝑡

𝑆𝑠𝑦 × 𝜋𝑑3
𝐷=
8𝑛𝑠 (1 + 𝜁)𝐹𝑚𝑎𝑥
𝐷
𝐶=
𝑑
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4𝐶 + 2
𝐾𝐵 =
4𝐶 − 3
8 × (1 + 𝜁) × 𝐹𝑚𝑎𝑥 × 𝐷
𝜏𝑠 =
𝜋 × 𝑑3
𝑆𝑠𝑦
𝑛𝑠 =
𝜏𝑠
𝑂𝐷 = 𝐷 + 𝑑
𝐼𝐷 = 𝐷 − 𝑑
𝐺 × 𝑑4 × 𝑦𝑚𝑎𝑥
𝑁𝑎 =
8 × 𝐷 3 × 𝐹𝑚𝑎𝑥
𝐿𝑠 = 𝑑 × (𝑁𝑎 + 2)

𝐿0 = 𝐿𝑠 + ((1 + 𝜁) × 𝑦𝑚𝑎𝑥 )
2.63𝐷
𝐿0𝑐𝑟 =
0.5
𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑐𝑜𝑠𝑡 × 𝛾 × 𝜋 2 × 𝑑2 × 𝑁𝑇 × 𝐷
𝑓𝑜𝑚 = −
4

For as-wound springs:

𝐴
𝑆𝑢𝑡 =
𝑑𝑚
𝑆𝑠𝑦 = 0.45 × 𝑆𝑢𝑡
𝑆𝑠𝑦
𝛼=
𝑛𝑠
8 × (1 + 𝜁) × 𝐹𝑚𝑎𝑥
𝛽=
𝜋 × 𝑑2

2𝛼 − 𝛽 2𝛼 − 𝛽 2 3𝛼
𝐶= + √( ) −
4𝛽 4𝛽 4𝛽

4𝐶 + 2
𝐾𝐵 =
4𝐶 − 3
𝐷 =𝑑×𝐶
𝑂𝐷 = 𝐷 + 𝑑
𝐺 × 𝑑4 × 𝑦𝑚𝑎𝑥
𝑁𝑎 =
8 × 𝐷 3 × 𝐹𝑚𝑎𝑥
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𝐿𝑠 = 𝑑 × (𝑁𝑎 + 2)

𝐿0 = 𝐿𝑠 + ((1 + 𝜁) × 𝑦𝑚𝑎𝑥 )

8 × (1 + 𝜁) × 𝐹𝑚𝑎𝑥 × 𝐷
𝜏𝑠 =
𝜋 × 𝑑3
𝑆𝑠𝑦
𝑛𝑠 =
𝜏𝑠
2.63𝐷
𝐿0𝑐𝑟 =
0.5
𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑐𝑜𝑠𝑡 × 𝛾 × 𝜋 2 × 𝑑2 × 𝑁𝑇 × 𝐷
𝑓𝑜𝑚 = −
4

MATLAB:
Using MATLAB code (Appendix A), we iterated using different diameters to find the following
springs and choose the correct design.
For As-wound, we got the following results:

Figure 16 Table of design for as-wound springs for diameters 6mm to 12mm.
24 | P a g e

Figure 17: Table of design for as-wound springs for diameters 13mm to 19mm.

For the set removed, we got the following results:

Figure 18Table of design for set removed springs for diameters 6mm till 12mm.

Figure 19 Table of design for set removed springs for diameters 13mm till 19mm.
25 | P a g e

The results of the as-wound springs didn’t match the design constraints, thus, a 14mm diameter
set removed springs was used.

𝐴 1974
𝑆𝑢𝑡 = 𝑚
= 0.108 = 1484.44𝑀𝑃𝑎
𝑑 14
𝑆𝑠𝑦 = 0.65 × 𝑆𝑢𝑡 = 964.89𝑀𝑃𝑎

𝑆𝑠𝑢 = 0.67 × 𝑆𝑢𝑡 = 994.57𝑀𝑃𝑎

4𝐶 + 2
𝐾𝐵 = = 1.33
4𝐶 − 3
8𝐾𝑏 × 𝐹𝑎 × 𝐷
𝜏𝑎 = = 155 𝑀𝑃𝑎
𝜋𝑑3
8𝐾𝑏 × 𝐹𝑚 × 𝐷
𝜏𝑚 = = 774.49 𝑀𝑃𝑎
𝜋𝑑3
8𝐾𝑏 × 𝐹𝑠 × 𝐷
𝜏𝑠 = = 1 GPa
𝜋𝑑3
𝜏𝑎
𝑟= = 0.2
𝜏𝑚

We will assume unpeened spring so 𝑆𝑠𝑎 = 241 𝑀𝑃𝑎 and 𝑆𝑠𝑚 = 379 𝑀𝑃𝑎
𝑆𝑠𝑎 𝑆 2
From Gerber: 𝑆𝑠𝑒
+ ( 𝑆𝑠𝑚) = 1
𝑠𝑢

Solving for 𝑆𝑠𝑒 we get 𝑆𝑠𝑒 = 281.94𝑀𝑃𝑎

Substituting in intersection coordinate for Gerber criteria and solving for 𝑆𝑠𝑎

𝑟 2 𝑆𝑠𝑢
2
2𝑆𝑠𝑒 2
𝑆𝑠𝑎 = × (−1 + √1 + ( ) ) = 456.51𝑀𝑃𝑎
2𝑆𝑠𝑒 𝑟𝑆𝑠𝑚

𝑆𝑠𝑎
𝑛𝑓 = 𝜏𝑎
= 2.94

𝑆𝑠𝑦
𝑛𝑠 = 𝜏𝑠
=1

The spring is safe for both fatigue and yielding and thus it won’t fail.
26 | P a g e

Results Summary:

Table 2 Summary of design process.

Component Challenges Key Results

Addressed Method Used

Carriage Fatigue under Stress and fatigue Safety factor against

overloading analysis + SolidWorks fatigue: 4.02. Maximum
Von Mises stress: 198.3
MPa at critical points.
Bolts Failure under Theoretical stress Yielding safety factor:
shear analysis+ Matlab 4.47 Final bolt
dimensions: M20x2.5
class 10.9 with grip
length 117.6 mm.
Springs Fatigue failure MATLAB-based spring Selected setremoved
in suspension analysis and Gerber spring: diameter 14 mm,
systems criterion fatigue-resistant under
cyclic loading.
27 | P a g e

Chapter 5: Conclusion

The structural and fatigue performance of the key components in the movable cantilever arm lifter
was successfully validated through detailed analysis. The carriage demonstrated a high safety
factor against fatigue (4.02), with a maximum Von Mises stress of 198.3 MPa, confirming its
reliability under repeated loading. The bolts, evaluated under shear stress using theoretical analysis
in MATLAB, achieved a yielding safety factor of 4.47, supporting the selection of M20x2.5 grade
10.9 bolts with sufficient grip length (117.6 mm). For the spring system, a MATLAB-based fatigue
analysis using the Gerber criterion led to the selection of a 14 mm diameter fatigue-resistant spring,
suitable for cyclic loading conditions. Overall, the component design meets mechanical safety and
endurance requirements, ensuring the durability and operational reliability of the lifter.
28 | P a g e

References
Zhou, M., Kim, J., & Patel, R. (2019). Structural Performance of Cantilever Beams under
Dynamic Loading. Journal of Structural Engineering, 145(4), 04019022.

Martínez, D., & Lee, S. (2020). Wear Analysis of Pivot Joints in Mobile Mechanisms. Mechanics
& Materials, 26(2), 141-152.

Singh, A., Jaber, M., & Al-Khatib, N. (2021). Stability Assessment of Mobile Lifting Arms.
International Journal of Mechanical Systems, 34(3), 211–218.

Johnson, D., & El-Rayes, K. (2017). Fatigue Life Improvement of Welded High-Strength Steel
Arms. Engineering Failure Analysis, 78, 104–114.

Tanaka, Y., Ogawa, H., & Fukuda, M. (2022). Optimization of Cantilever Structures Using Finite
Element Methods. Computational Design Journal, 12(1), 33–45.

SOLIDWORKS. (2024). SOLIDWORKS (Version 2024). Retrieved from

[Link]

The MathWorks, I. (2024). MATLAB (R2024a). Retrieved from

[Link]
29 | P a g e

Appendix A
Beam:
% Clear previous work
clear; clc; close all;

% --- INPUTS ---

F = input('Enter the Load applied at the end (in N): ');
L = input('Enter the Length of the cantilever arm (in meters): ');
b = input('Enter the Width of the arm cross-section (in meters): ');
h = input('Enter the Height of the arm cross-section (in meters): ');
E = input('Enter the Young''s Modulus of the material (in Pascals): ');
Sut = input('Enter the Ultimate Strength of the material (in Mega Pascals): ');
Sy = input('Enter the Yield Strength of the material (in Mega Pascals): ');

% --- Cross-section Properties ---

I = (b * h^3) / 12; % Moment of inertia
c = h / 2; % Distance from neutral axis

% --- Static Calculations ---

M_max = F * L; % Maximum Bending Moment
sigma_bending = (M_max * c) / I; % Maximum Bending Stress (alternating stress)
delta_max = (F * L^3) / (3 * E * I); % Maximum Deflection

n_yield = Sy / (2 * sigma_bending/1e6); % Static Safety Factor (Yielding)

% --- Marin Factors for Fatigue Endurance Limit Se ---

% Surface Finish Factor (Ka) -- Assuming machined surface
a_surface = 4.51; % for machined surface
b_surface = -0.265;
Ka = a_surface * (Sut)^b_surface; % Corrected to work in MPa

% Size Factor (Kb) -- non-rotating rectangular section

de = 0.808 * sqrt(b * h); % Equivalent diameter in meters
de_mm = de * 1000; % Convert to mm
if de_mm <= 51
Kb = 1;
elseif de_mm <= 254
Kb = 1.51 * de_mm^(-0.157);
else
Kb = 0.6;
end

% Load Factor (Kc) -- assuming bending

Kc = 1;

% Temperature Factor (Kd) -- assuming room temperature

Kd = 1;

% Reliability Factor (Ke) -- assuming 99% reliability

Ke = 1;

% Miscellaneous-effects Factor (Kf) -- no special effects

30 | P a g e

Kf = 1;

% Calculate Se'
Se_prime = (0.504 * Sut); % Unmodified rotating beam endurance limit

% Apply Marin Factors

Se = (Ka * Kb * Kc * Kd * Ke * Kf * Se_prime);

% --- Goodman Criterion for Fatigue ---

sigma_a = sigma_bending; % Alternating stress = sigma_bending (assuming zero-mean
loading)
sigma_m =sigma_bending ; % Mean stress = 0 for fully reversed loading

% Goodman Equation:
% (sigma_a / Se) + (sigma_m / Sut) = 1 / nf
nf_goodman = (1 / ((sigma_a / Se) + (sigma_m / Sut)))*1e6;

% --- OUTPUTS ---

fprintf('\n---- Results ----\n');
fprintf('Moment of Inertia (I) = %.6e m^4\n', I);
fprintf('Maximum Bending Moment (M_max) = %.2f N.m\n', M_max);
fprintf('Maximum Bending Stress (σ_bending) = %.2f MPa\n', sigma_bending / 1e6);
fprintf('Static Safety Factor against Yielding (n_yield) = %.2f\n', n_yield);
fprintf('Maximum Deflection at Free End (δ_max) = %.2f mm\n', delta_max * 1000);

fprintf('\n---- Fatigue Analysis ----\n');

fprintf('Unmodified Endurance Limit (Se'') = %.2f MPa\n', Se_prime );
fprintf('Surface Finish Factor (Ka) = %.3f\n', Ka);
fprintf('Size Factor (Kb) = %.3f\n', Kb);
fprintf('Load Factor (Kc) = %.3f\n', Kc);
fprintf('Reliability Factor (Ke) = %.3f\n', Ke);
fprintf('Miscellaneous-effects Factor (Kf) = %.3f\n', Kf);
fprintf('Modified Endurance Limit (Se) = %.2f MPa\n', Se );
fprintf('Goodman Fatigue Safety Factor (nf) = %.2f\n', nf_goodman);

% Optional Warnings
if n_yield < 2
fprintf('⚠️ Static Warning: Low safety factor against yielding!\n');
end
if nf_goodman < 1.5
fprintf('⚠️ Fatigue Warning: Low fatigue safety factor!\n');
end
31 | P a g e

Appendix B
Bolt:
% Clear workspace and command window
clear; clc;

% Prompt user for bolt parameters

d_shank = input('Enter the diameter of the shank (in mm): '); % Diameter of the shank
l_unthreaded = input('Enter the length of the unthreaded portion with a negative sign
(in mm): '); % Length of the unthreaded portion
l_threaded = input('Enter the length of the threaded portion with a negative sign (in
mm): '); % Length of the threaded portion
d_head = input('Enter the diameter of the head (in mm): '); % Diameter of the head
h_head = input('Enter the height of the head (in mm): '); % Height of the head
thread_pitch = input('Enter the pitch of the thread (in mm): '); % Pitch of the
thread
thread_depth = input('Enter the depth of the thread (in mm): '); % Depth of the
thread

% Calculate volumes
volume_unthreaded = pi * (d_shank / 2)^2 * l_unthreaded; % Volume of the unthreaded
portion
volume_threaded = pi * (d_shank / 2)^2 * l_threaded; % Volume of the threaded portion
(cylinder)
volume_head = (1/3) * pi * (d_head / 2)^2 * h_head; % Volume of the head (as a
frustum)
total_volume = volume_unthreaded + volume_threaded + volume_head; % Total volume

% Display results
fprintf('Bolt Properties:\n');
fprintf('Volume of the Unthreaded Portion: %.6f cubic mm\n', volume_unthreaded);
fprintf('Volume of the Threaded Portion: %.6f cubic mm\n', volume_threaded);
fprintf('Volume of the Head: %.6f cubic mm\n', volume_head);
fprintf('Total Volume: %.6f cubic mm\n', total_volume);

% Visualization of the bolt

figure;

% Create the head (cylinder)

[X_head, Y_head, Z_head] = cylinder(d_head / 2, 50); % Cylinder for head
Z_head = Z_head * h_head; % Scale the height of the cylinder

% Create the unthreaded portion (cylinder)

[X_unthreaded, Y_unthreaded, Z_unthreaded] = cylinder(d_shank / 2, 50); % Cylinder
for unthreaded portion
Z_unthreaded = Z_unthreaded * l_unthreaded; % Scale the height of the cylinder
Z_unthreaded = Z_unthreaded + h_head; % Position the unthreaded portion below the
head

% Create the threaded portion (cylinder)

[X_threaded, Y_threaded, Z_threaded] = cylinder(d_shank / 2, 50); % Cylinder for
threaded portion
Z_threaded = Z_threaded * l_threaded; % Scale the height of the cylinder
32 | P a g e

Z_threaded = Z_threaded + h_head + l_unthreaded; % Position the threaded portion

below the unthreaded portion

% Plot the head, unthreaded and threaded portions

surf(X_head, Y_head, Z_head, 'FaceColor', 'c', 'EdgeColor', 'none'); % Head
hold on;
surf(X_unthreaded, Y_unthreaded, Z_unthreaded, 'FaceColor', 'g', 'EdgeColor',
'none'); % Unthreaded
surf(X_threaded, Y_threaded, Z_threaded, 'FaceColor', 'b', 'EdgeColor', 'none'); %
Threaded

% Create threads as a helical shape

num_threads = l_threaded / thread_pitch; % Number of threads
theta = linspace(0, num_threads * 2 * pi, 100); % Angle for threads
z_thread = linspace(0, l_threaded, 100); % Z coordinates for threads

% Helix for threads

x_thread = (d_shank / 2 + thread_depth) * cos(theta); % X coordinates for threads
y_thread = (d_shank / 2 + thread_depth) * sin(theta); % Y coordinates for threads

% Plot the threads

plot3(x_thread, y_thread, z_thread + h_head + l_unthreaded, 'k', 'LineWidth', 1.5); %
Threads

% Set plot limits and labels

xlabel('X (mm)');
ylabel('Y (mm)');
zlabel('Z (mm)');
title('Bolt Visualization with User Input Parameters');
axis equal;
grid on;
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Appendix C
Set-Removed Spring
% Clear workspace and command window
clear; clc;

% Design factors
ns = 1.2; % Design factor at solid height
zeta = 0.15; % Robust linearity factor

% Prompt user for input parameters for yield strength calculation

A = input('Enter the material constant A (MPa·mm^m): '); % Material constant
d_values = input('Enter a vector of wire diameters (mm) as [d1, d2, ...]: '); % Wire
diameters
m = input('Enter the exponent m: '); % Exponent for diameter

material_cost = input('Enter material cost: ');

% Prompt user for other input parameters

F_max = input('Enter the maximum load (N): ');

% Prompt user for other input parameters

y_max = input('Enter the maximum deflection (mm): ');
solid_height_limit = input('Enter the maximum solid height (mm): ');
free_length_limit = input('Enter the maximum free length (mm): ');

% Material properties (assumed for music wire)

G = input('Enter the shear modulus (GPa): ') * 1e3; % Convert GPa to MPa

% Initialize arrays to store results

d_results = [];
D_results = [];
C_results = [];
OD_results = [];
Na_results = [];
Ls_results = [];
L0_results = [];
L0cr_results = [];
nS_results = [];
fom_results = [];

% Loop over each diameter value

for i = 1:length(d_values)
d = d_values(i); % Get the current diameter from the vector

% Calculate ultimate strength (Sut) using the formula Ssy = A / d^m

S_ut = A / (d^m); % Yield strength in MPa
S_sy = 0.65 * S_ut;

% Calculate outer diameter (D) and spring index (C)

D=(S_sy*3.14*(d^3))/(8*ns*(1+zeta)*F_max);
34 | P a g e

C=D/d ; % Coil diameter in mm

OD = D + d; % Outer diameter in mm

% Calculate the number of active turns (Na)

Na = (G * d^4 * y_max) / (8 * D^3 * F_max); % Number of active turns

% Calculate solid height (Ls) and free length (L0)

Ls = d * (Na + 2); % Solid height
L0 = Ls + (1 + zeta) * y_max; % Free length

% Calculate the Shear Stress \tau s

taus = ((8 * (1 + zeta) * F_max * D)) / (3.14 * d^3);

% Calculate the actual factor of safety nS

nS = S_sy / taus;

% Calculate the critical initial length L0cr

L0cr = (2.63 * D) / 0.5;

% Calculate the figure of merit

fom = -((material_cost) * (1 * 9.85 * (d^2) * (Na + 2) * D)) / (4 *
solid_height_limit^3);

% Store results in the arrays

d_results = [d_results; d];
D_results = [D_results; D];
C_results = [C_results; C];
OD_results = [OD_results; OD];
Na_results = [Na_results; Na];
Ls_results = [Ls_results; Ls];
L0_results = [L0_results; L0];
L0cr_results = [L0cr_results; L0cr];
nS_results = [nS_results; nS];
fom_results = [fom_results; fom];
end

% Create a table to display the results

results_table =table
(d_results,D_results,C_results,OD_results,Na_results,Ls_results,L0_results,L0cr_resul
ts,nS_results,fom_results);
% Transpose the table
transposed_table = results_table;

% Display the title

disp('--- Results of Spring Design ---');

% Display the transposed table

disp(transposed_table);

Aswound Spring:
% Clear workspace and command window
clear; clc;
35 | P a g e

% Design factors
ns = 1.2; % Design factor at solid height
zeta = 0.15; % Robust linearity factor

% Prompt user for input parameters for yield strength calculation

A = input('Enter the material constant A (MPa·mm^m): '); % Material constant
d_values = input('Enter a vector of wire diameters (mm) as [d1, d2, ...]: '); % Wire
diameters
m = input('Enter the exponent m: '); % Exponent for diameter
x = input('Enter the x value according to wire type: '); % Wire type coefficient
material_cost = input('Enter material cost: ');

% Prompt user for other input parameters

F_max = input('Enter the maximum load (N): ');

% Prompt user for other input parameters

y_max = input('Enter the maximum deflection (mm): ');
solid_height_limit = input('Enter the maximum solid height (mm): ');
free_length_limit = input('Enter the maximum free length (mm): ');

% Material properties (assumed for music wire)

G = input('Enter the shear modulus (GPa): ') * 1e3; % Convert GPa to MPa

% Initialize arrays to store results

d_results = [];
D_results = [];
C_results = [];
OD_results = [];
Na_results = [];
Ls_results = [];
L0_results = [];
L0cr_results = [];
nS_results = [];
fom_results = [];

% Loop over each diameter value

for i = 1:length(d_values)
d = d_values(i); % Get the current diameter from the vector

% Calculate ultimate strength (Sut) using the formula Ssy = A / d^m

S_ut = A / (d^m); % Yield strength in MPa
S_sy = x * S_ut;

% Calculate alpha and beta

alpha = S_sy / ns; % constant
beta = (8 * (1 + zeta) * F_max) / (3.14 * (d^2)); % constant

% Calculate the spring index

C1 = ((2 * alpha) - beta) / (4 * beta); % constant
C2 = (3 * alpha) / (4 * beta); % constant
C = C1 + sqrt(C1^2 - C2); % spring index C

% Calculate the BERGSTESSER FACTOR

KB = ((4 * C) + 2) / ((4 * C) - 3);
36 | P a g e

% Calculate outer diameter (D) and spring index (C)

D = d * C; % Coil diameter in mm
OD = D + d; % Outer diameter in mm

% Calculate the number of active turns (Na)

Na = (G * d^4 * y_max) / (8 * D^3 * F_max); % Number of active turns

% Calculate solid height (Ls) and free length (L0)

Ls = d * (Na + 2); % Solid height
L0 = Ls + (1 + zeta) * y_max; % Free length

% Calculate the Shear Stress \tau s

taus = (KB * ((8 * (1 + zeta) * F_max * D)) / (3.14 * d^3));

% Calculate the actual factor of safety nS

nS = S_sy / taus;

% Calculate the critical initial length L0cr

L0cr = (2.63 * D) / 0.5;

% Calculate the figure of merit

fom = -((material_cost) * (1 * 9.85 * (d^2) * (Na + 2) * D)) / (4 *
solid_height_limit^3);

% Store results in the arrays

d_results = [d_results; d];
D_results = [D_results; D];
C_results = [C_results; C];
OD_results = [OD_results; OD];
Na_results = [Na_results; Na];
Ls_results = [Ls_results; Ls];
L0_results = [L0_results; L0];
L0cr_results = [L0cr_results; L0cr];
nS_results = [nS_results; nS];
fom_results = [fom_results; fom];
end

% Create a table to display the results

results_table =table
(d_results,D_results,C_results,OD_results,Na_results,Ls_results,L0_results,L0cr_resul
ts,nS_results,fom_results);
% Transpose the table
transposed_table = results_table;

% Display the title

disp('--- Results of Spring Design ---');

% Display the transposed table

disp(transposed_table);