In today’s world of growing competition, all industries are trying their best to give the components of high quality with minimum expenditure. So in present work a new semi-elliptical boom has been selected to replace the conventional boom, which is usually made of rectangular. In particular, the study wants to substitute the rectangular section for Semi-elliptical section. This change lightens the weight of the boom. For this purpose, boom with semi-elliptical cross-section has been modeled using cad software pro/E wildfire 4.0. Using VB program automatic calculation module (UPAS), the static force at different working condition of the boom calculated. Then Finite element analysis has been done to determine the static stress at a given load condition using software ANSYS 12. The result shows that total weight is reduced by 5%. The value of maximum stress and displacement is 115.663MPa and 12.885 mm respectively. Thus the structure is capable of withstanding the maximum stress. The structure is failsafe. In this paper only static stress analysis is done.

In manufacturing industry investors are always looking for economical and safe designs to cope up with the increasing demands of competitive markets. Keeping this objective in mind, arm of CE125 face shovel hydraulic excavator was re-designed to decrease manufacturing cost by reducing weight while keeping the stress approximately same as was used in the conventional design. For this purpose Pro/EngineerTM was used to generate Computer Aided Drawing (CAD) where cross section and inner structure of the design were kept to be semi-elliptical which helped to decrease the weight of the arm significantly. Initial stress analysis was also done in the same CAD software as it is quick and optimization can be done quickly. However sometimes it does not give accurate results because of poor meshing, so final analysis was done in AnsysTM. Analysis in AnsysTM calculated the stress to be 114 MPa while displacement came out to be 3.8 mm. Comparison of two models showed that the weight of new design is 5.1% less than the conventional one.