402-564-3456 [email protected]

Machine Design of Hydraulic Boom

Project Success Description

A farm-equipment manufacturer hired REDI Engineering, Inc. as part of their product-development team to design a rugged hydraulic boom used on a high-capacity hay-grinding machine. Ground hay is part of the diet in beef-cattle finishing operations. To satisfy customer requirements, extending horizontal boom reach and increasing lift capacity of the hydraulic boom were primary design goals. REDI Engineering analyzed properties of component cross sections and structural stress for the boom assembly. Final horizontal boom reach was 32.0 feet with a lift capacity of about 2,000 pounds. So design progress could be quickly communicated with non-engineers, the illustration on the left was created to exhibit lift capacity of the boom at various horizontal and vertical points. For example, the lift capacity 25 feet horizontally from the boom’s pivot point elevated 10 feet is 4,291 pounds. Values for the chart were generated using computer simulation. Results of the simulation agreed with field results and agreed with the known performance of the manufacturer’s existing-product line. After results were confirmed, computer simulation was used for predicting stress within components of a virtual prototype. The performance of a virtual prototype and effects of design changes could be quickly analyzed and adjustments made to design. Design insight was gained quickly when effects of design tweaks would unfold in the performance of a virtual prototype.

John Thomazin was the mechanical engineer who analyzed the boom’s geometric properties, structure, material selection, and stress distribution. Key activities to achieve design success for this project included:

  • Creation of software to calculate for any boom configuration:
    • Shear diagrams;
    • Moment diagrams;
    • Section properties of boom components;
    • Internal stresses within components; and
    • Direction and magnitude of reaction forces.
  • Identification of high-stress areas within components.
  • Identifying configurations producing high-stresses and high-forces.
  • Identifying areas within components having stress concentrations.
John Thomazin MSME, P.E.

John Thomazin MSME, P.E.

Mechanical Engineering | Farm-Equipment Design

John is an adjunct engineering instructor and founder of REDI Engineering. John is an expert in finite element analysis including machine design, fatigue and nonlinear material response, failure modes, value engineering, and product liability. His understanding of the response of different types of materials extends to ferrous metals (steel), non-ferrous metals (e.g. aluminum, brass, copper), composites, rubber, plastics, soils, concrete, and other material types. John’s engineering experience includes structural analysis, fatigue, building design, product development, failure modes and effects analysis (FMEA), and forensic engineering. He enjoys solving difficult problems and creating economical solutions. He is a member of the National Society of Professional Engineers and a member of the National Academy of Building Inspection Engineers. He has a Bachelor of Science degree in Mathematics, a Master of Science in Mechanical Engineering, and is a licensed Professional Engineer in the State of Nebraska.