The results show that, under the given simulation environment, the highly stressed fields occur in the boom, crowd arm, boom-point sheave and hoist rope. The simulated results are validated using existing test data. Detailed simulation of this virtual shovel simulator is carried out to find the front-end driving loads and torques, component stress distributions and nodal stresses under varying formation conditions. A virtual prototype simulator, based on the geometry of the P&H 4100A cable shovel, is developed to capture a three-dimensional interactive surface mining environment. The models are solved in the ADAMS/NASTRAN/FLEX simulation environments. In this paper, rigid and flexible multibody dynamic theories are used to develop component stress loading models of the cable shovel assembly. The conventional design process, which uses physical shovel simulation studies, is very costly and time consuming for achieving statistically significant results. High static and the repeated dynamic impact loading of a shovel’s frontend assembly could exceed component yield strength, resulting in component failure. Poorly fragmented hard rock formations and the random occurrence of hard boulders in soft formations cause extreme variability of material diggability, resulting in varying shovel stress loading. Cable shovels are used in the primary excavation of in situ and/or prefragmented formations in surface mining operations.
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