Structural optimization of a Vibrocat carriage using Finite Element Analysis

Abstract

Structural failures caused by fatigue represent one of the main challenges in heavy industrial equipment operating under severe loading conditions. This study evaluates the structural performance of a Vibrocat head carriage subjected to a critical load of 200 kN through Computer-Aided Design (CAD) and Finite Element Analysis (FEA). The original geometry was reconstructed and numerically analyzed using SolidWorks Simulation, considering ASTM A36 structural steel and linear elastic material behavior. The initial results revealed a maximum Von Mises stress of 617.86 MPa and a safety factor of 0.40, confirming the occurrence of localized yielding and explaining the recurrent fatigue failures observed during operation. Based on these findings, the head mounting plate was redesigned and validated under identical boundary conditions. The optimized configuration reduced the maximum stress to 126.63 MPa and increased the safety factor to 1.97, maintaining the component entirely within the elastic regime. The proposed reinforcement proved technically feasible, economically viable, and capable of significantly improving structural reliability and operational safety.