Design and Analysis of Cattle Slaughtering Aid Frame with Three Load Variations Using Finite Element Method (FEA) ^†

Abstract

The design and structural analysis of a cattle slaughtering frame is essential to ensure the safety, efficiency, and durability of the facility. This research was conducted in farms and slaughterhouses to analyze the performance of cattle slaughtering frames under three load variations using the finite element method (FEA). The frame model was created using Autodesk Inventor and simulated in Ansys, considering material properties, dimensions, and frame configuration. The simulated loads represented cow weights ranging from 500 kg/4905 N to 1500 kg/14,715 N. The analysis results showed the distribution of stress and deformation across the frame structure. The highest stress occurred under the 1500 kg/14,715 N load but remained within safe limits. The frame, designed using 1040 carbon steel, demonstrated the ability to withstand a maximum load of 1500 kg/14,715 N with an acceptable safety factor. Although stress and deflection increased with higher loads, the structure stayed within allowable tolerances. These findings confirm that FEA is an effective tool for optimizing structural performance before fabrication. The study provides recommendations for safer and more efficient designs, particularly in selecting materials and reinforcing critical areas. This research is expected to serve as a reference for improving the quality of cattle slaughtering facilities in farms and abattoirs.

1. Introduction

The process of slaughtering animals, especially cows, requires sturdy and safe tools to ensure a smooth and safe process, as well as ensuring the process is in accordance with applicable safety standards [1,2,3]. One of the vital components of slaughtering activities is the frame of the auxiliary equipment that functions to hold and support the cow’s body during the process [4,5]. A poorly designed frame can lead to instability, risk of accidents, or even structural failure, which can jeopardize worker safety and reduce the effectiveness of the slaughtering process [6,7].

With technological advances in the industrial world, the design of cattle slaughtering aids can now be optimized using engineering simulations, one of which is the finite element analysis (FEA) method. FEA is a numerical analysis method that allows for the simulation and evaluation of the strength and durability of materials in complex engineering components [8,9]. With the FEA approach, we can predict the behavior of the skeletal structure of cattle slaughtering aids under the influence of various types of loads received during the slaughtering process [10].

The load received by the frame of a cattle slaughtering aid can vary depending on a number of factors, such as the weight of the cow, the position of the cow’s body during the slaughtering process, and variations in the methods and techniques used. Therefore, it is important to analyze the ability of the auxiliary frame to withstand loads under various operational conditions that may occur [11,12,13,14]. For this reason, this study uses three loading variations that represent the loads commonly encountered in the cattle slaughtering process, namely 500 kg/4905 N, 1000 kg/9810 N, and 1500 kg/14,715 N.

The reason for choosing the three loading variations is to cover the variation in the weight of cattle that is often encountered in the slaughtering industry and slaughterhouses. A load of 500 kg/4905 N represents a cow of smaller or younger size, while a load of 1000 kg/9810 N represents an average-sized cow, and 1500 kg/14,715 N represents an adult cow of large size [15,16]. By considering these three loading variations, it is hoped that a more comprehensive picture of the ability of the auxiliary frame to withstand varying loads can be obtained, as well as to ensure a frame design that can function optimally under various conditions.

This study aims to design and analyze the frame of cattle slaughtering aids using FEA by considering the three loading variations described above. Through this research, it is hoped that an efficient, safe, and durable frame design can be obtained which is able to withstand the load optimally without experiencing deformation or structural failure. The results of this study will contribute to improving the quality of cattle slaughtering equipment frames among farms and slaughterhouses, as well as supporting safety and efficiency in the implementation of the slaughtering process.

2. Methods

2.1. Model Design

The design of the cattle cutting tool was made using Autodesk Inventor 2024 software [17]. The dimensions and shape of the tool have been adjusted to the size of the cow. The frame design of the cow slaughtering aid can be seen in Figure 1.

Geometric models that were created using Autodesk Inventor software were then exported into a format compatible with Ansys 2024 R1 software.

2.2. Load and Material Variation Analysis

This study uses three loading variations that represent the loads commonly encountered in the cattle slaughtering process, namely 500 kg/4905 N, 1000 kg/9810 N, and 1500 kg/14,715 N. Then, the process was simulated using 1040 carbon steel material. Carbon steel 1040 is a medium-carbon steel that is often used in a wide variety of structural and mechanical applications [18,19,20,21,22]. The chemical composition of carbon steel 1040 can be seen in

Table 1. Chemical composition of carbon steel 1040.

Element	Fill
Iron, Fe	98.6–99
Manganese, Mn	0.6–0.9
Carbon, C	0.37–0.44
Sulfur, S	$\le$0.05
Phosphorus, P	$\le$0.04

below.

The mechanical properties of carbon steel 1040 can be seen in

Table 2. Mechanical properties of carbon steel 1040.

Property	Metric
Tensile strength	620 MPa
Modulus of elasticity	200 GPa
Yield strength	350 MPa
Density	$7850 \mathrm{kg}/{\mathrm{m}}^3$
Hardness	149–170 HB (Brinell Hardness)

below.

2.3. Finite Element Method Analysis (FEA)

The simulation was carried out using Ansys software with the finite element analysis (FEA) completion method with the following steps:

• Import the cow cutter model file in IGES (.igs) format.
• Select the type of static structural analysis in the toolbox.
• Drag the geometry of the model on static structural geometry.
• Select the material types in Engineering Data.
• Determine the placement of support on the structure, as shown in Figure 2 below.

In the analysis of the finite element method (FEA), the support point is the location on the structure where the loading or force reaction occurs. These points are usually used to hold the load and prevent movement in a certain direction.

The determination of the load location and the magnitude of the load variation received by the structure based on the predetermined load amount can be seen in Figure 3.

In finite element method (FEA) analysis, the point of the load is the location on the structure where a force or moment is applied. This point is very important because it determines how the structure will respond to external loads.

3. Results and Discussion

Based on the analysis of the finite element method (FEA) on cattle cutting tools with three load variations, the following results were obtained:

3.1. Light Load 500 kg/4905 N

The maximum deflection (total deformation) in cattle cutting tools with light loads occurs at the joints at the base with a value of δmax = 1.8108 mm, as shown in Figure 4.

The maximum yield stress (equivalent Von Mises stress) in cattle cutting tools with light loads occurs at the joints of each side of the bottom with a max σy value = 54.037 MPa, as shown in Figure 5.

Yield strain (equivalent elastic strain) in cattle cutting tools with light loads occurs at the joints of each lower side with a value of εy max = 0.00025711 mm/mm, as shown in Figure 6.

The safety factor (safety factor) on this lightweight cattle cutting tool shows a value of 6.4863, as shown in Figure 7.

3.2. Medium Load 1000 kg/9810 N

The maximum deflection (total deformation) in the cattle cutting tool with medium load occurs at the joint at the base with a value of δmax = 3.6216 mm, as shown in Figure 8.

The maximum yield stress (equivalent von Mises stress) in cattle cutting tools with medium loads occurs at the joints on each side of the bottom with a max σy value = 108.07 MPa, as shown in Figure 9.

Yield strain (equivalent elastic strain) in cattle cutting tools with moderate loads occurs at the joints of each lower side with a value of εy max = 0.00051423 mm/mm, as shown in Figure 10.

The safety factor in this medium-load cattle cutting tool shows a value of 3.2432, which is shown in Figure 11.

3.3. Heavy Load 1500 kg/14,715 N

The maximum deflection (total deformation) in the cattle cutting tool with heavy loads occurs at the joints at the base with a value of δmax = 5.4324 mm, as shown in Figure 12.

The maximum yield stress (equivalent von Mises stress) in cattle cutting tools with heavy loads occurs at the joints of each bottom side with a value of σy max = 162.11 MPa, as shown in Figure 13.

Yield strain (equivalent elastic strain) in cattle cutting tools with moderate loads occurs at the joints of each lower side with a value of εy max = 0.00077134 mm/mm, as shown in Figure 14.

The safety factor in this medium-load cattle cutting tool shows a value of 2.1621, which is shown in Figure 15.

The simulation results show that the highest voltage distribution occurs at each major junction point of the frame. The frame with 1040 carbon steel material exhibits an adequate safety factor for all load variations, with maximum deformation remaining within tolerance limits. However, an increase in load results in an increase in tension at certain critical points, which can be reduced by reinforcing certain parts of the frame.

4. Conclusions

Based on the results of the analysis using the finite element method (FEA), the frame of the cattle slaughtering aid designed using 1040 carbon steel material is able to withstand a load of up to 1500 kg/14,715 N with a safety factor that is still within safe limits. The total maximum stress and deflection distribution indicates that the structure remains within the allowable design tolerances. With the increase in the load from 500 kg/4905 N to 1500 kg/14,715 N, there is an increase in tension and deformation, but the frame can still function safely. Therefore, the application of FEA in the design of this frame is effective to evaluate performance before fabrication so as to improve efficiency and safety in the slaughter process.