Analysis of a Lifting Fixture to Hold a Steel Mandrel Horizontally from one End Support Page: 2 of 17
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A lifting fixture (drawing number 3823.1 13-MD-372382) that lifts large steel mandrels from one end
through the mandrel's end support web is described. The mandrels are used as a mold to form carbon fiber
cylinders. The mandrels are held from one end to allow the carbon cylinder to be pulled horizontally off the
mandrel. Only mandrels as described in drawing #'s 3823.113-MD-358992 and 3823.113-MD-358994 are
lifted by the fixture. The largest mandrel is 41 inches in diameter, 120 inches long, and weighs
approximately 3,000 lbs. A detailed procedure for removing the carbon cylinder from the steel mandrel is
given in the Appendix.
The fixture is to be supported only using Fermilab Forklift #10207 or equivalent. The forklift has a
nameplate capacity of 12,000 lbs 24 inches from the mast at an elevation of 130 inches from the floor. The
forklift forks must be removed from the truck pnor to using the fixture. The forklift is to be used to support
the mandrels only during the lifting operation and is not to be used to transport the mandrels.
Stresses at the lifting fixture are shear stresses on the support brackets due to the overall weight of the
mandrel and moment loads due to the cantilever style support. The moment on the forklift due to the
overhanging weight of the mandrel is calculated. Stresses in the mandrel due to the method of support are
Expected Size and Weight of the Mandrels:
The total weight of a mandrel is based on the weight of the rolled skin that forms the outside barrel and the
support webs. The journals are stubs welded into the end support webs and do not significantly contribute
to the weight of the mandrel. The length of mandrels #1 and #2 is approximately 76 inches and of mandrels
#3 thru #8 is 110 inches. The expected wall thickness for each mandrel is a '/2 inch. The end support webs
are 1" thick (weight calculations are conservatively based on solid support webs). Mandrels #3 thru #8 also
have a 1" thick center web for additional support. The density of steel used is 0.284 lb/in3. Weights and
dimensions of all mandrels are given in Table 1. The total moment on the lifting fixture is calculated as the
total mandrel weight multiplied by half the mandrel length.
Table 1. Mandrel Wei hts and Dimensions.
SUPPORT TOTAL MOMENT ON
OUTER MANDREL WALL WEB MANDREL LIFTING
MANDREL # DIAMETER LENGTH WEIGHT WEIGHT WEIGHT FIXTURE
(in) (in) (lbs) (lbs) (lbs) in.lbs
1 15.156 76 515 89 604 22,952
2 19.018 - 76 645 145 790 30,020
3 22.864 110 1,122 320 1,442 79,310
4 26.738 110 1,314 _443 1,757 96,635
5 30.602 110 1,502 586 2,088 114,840
6 34.464 110 1,691 749 2,440 134,200
7 38.326 110 1,881 932 2,813 154,715
8 40.292 110 1,977 1,033 3,010 165,550
The forklift has a nameplate capacity of 12,000 lbs with the load centered 24 inches from the mast at 130
inches of elevation. The total moment the Forklift can support is 288,000 in lbs. Using Table 1, the lowest
safety factor on the load capacity is approximately 4 and the lowest safety factor on the moment capacity is
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Cease, H. Analysis of a Lifting Fixture to Hold a Steel Mandrel Horizontally from one End Support, report, April 7, 1999; Batavia, Illinois. (digital.library.unt.edu/ark:/67531/metadc843304/m1/2/: accessed October 22, 2018), University of North Texas Libraries, Digital Library, digital.library.unt.edu; crediting UNT Libraries Government Documents Department.