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<p>Excavator dozer blades experience severe operational stresses that can lead to premature failure at welded joints and connection points. This study employed Finite Element Analysis (FEA) to investigate stress distribution in the HMK 230LC dozer blade and develop design optimizations balancing structural integrity with manufacturing efficiency. Crucially, the analysis identifies zero-degree upper-group alignment where the excavator’s superstructure is centered over the blade as the governing worst-case loading condition, a scenario underrepresented in prior literature. Systematic modifications including 50% increase in mirror sheet thickness and optimization of box profile dimensions to 150 × 200 × 8&#xa0;mm reduced welding stresses by 14% while maintaining Von Mises stresses below allowable limits (235&#xa0;MPa). The stress limit for welded regions (140&#xa0;MPa) is justified via International Institute of Welding (IIW) FAT class 80 recommendations, yielding an estimated fatigue life exceeding 80,000 cycles under variable amplitude loading. The optimized design achieved 24% reduction in total weld length, 21% decrease in manufacturing time, and 4.6% weight reduction through elimination of unnecessary bending and welding operations. Analytical equilibrium verification confirms FEA-predicted reaction forces within 3.2% error. This research provides a generalizable, kinematics-informed FEA-driven framework for heavy machinery optimization, demonstrating how computational analysis can guide design decisions that simultaneously improve structural performance, manufacturing feasibility, and cost-effectiveness.</p>

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Optimization of an excavator dozer blade using the finite element method: evaluating upper group alignment at zero degrees to the lower group

  • 期刊论文

  • 发表日期：

    2026年1月5日

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  • Demiral Akbar,
  • Harun Çeli̇k,
  • Tolga Dursun

摘要

Excavator dozer blades experience severe operational stresses that can lead to premature failure at welded joints and connection points. This study employed Finite Element Analysis (FEA) to investigate stress distribution in the HMK 230LC dozer blade and develop design optimizations balancing structural integrity with manufacturing efficiency. Crucially, the analysis identifies zero-degree upper-group alignment where the excavator’s superstructure is centered over the blade as the governing worst-case loading condition, a scenario underrepresented in prior literature. Systematic modifications including 50% increase in mirror sheet thickness and optimization of box profile dimensions to 150 × 200 × 8 mm reduced welding stresses by 14% while maintaining Von Mises stresses below allowable limits (235 MPa). The stress limit for welded regions (140 MPa) is justified via International Institute of Welding (IIW) FAT class 80 recommendations, yielding an estimated fatigue life exceeding 80,000 cycles under variable amplitude loading. The optimized design achieved 24% reduction in total weld length, 21% decrease in manufacturing time, and 4.6% weight reduction through elimination of unnecessary bending and welding operations. Analytical equilibrium verification confirms FEA-predicted reaction forces within 3.2% error. This research provides a generalizable, kinematics-informed FEA-driven framework for heavy machinery optimization, demonstrating how computational analysis can guide design decisions that simultaneously improve structural performance, manufacturing feasibility, and cost-effectiveness.