Optimization of an Excavator Dozer Blade Using the Finite Element Method: Evaluating Upper Group Alignment at Zero Degrees to the Lower Group

Optimization of an Excavator Dozer Blade Using the Finite Element Method: Evaluating Upper Group Alignment at Zero Degrees to the Lower Group | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Optimization of an Excavator Dozer Blade Using the Finite Element Method: Evaluating Upper Group Alignment at Zero Degrees to the Lower Group Demiral Akbar, Harun ÇELİK, Tolga DURSUN This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-5915133/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 05 Jan, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 4 You are reading this latest preprint version Abstract The Finite Element Analysis (FEA) conducted on the HMK 230LC dozer blade provided valuable insights into the structural behavior and stress distribution under various operational conditions. The analysis identified critical stress concentrations, particularly at welded joints and connection points, with maximum principal stresses reaching 120 MPa. These areas, influenced by geometric changes and loading conditions, were essential for evaluating the structural integrity and durability of the dozer blade. Design modifications, such as increasing the mirror sheet thickness by 50%, significantly reduced bending effects and improved load distribution, resulting in a 14% reduction in welding stresses at critical joints. This adjustment helped maintain stress levels within safe operational limits, improving overall structural reliability. Re-analysis post-modification confirmed a significant reduction in localized stress concentrations and bending effects, enhancing resistance to mechanical fatigue and increasing structural durability. The study also emphasized the importance of high-quality welding, especially at junctions between the main support and blade arms, to prevent stress-induced failures. Recommendations for further improvements include post-weld heat treatments, material reinforcements, and advanced welding techniques. The study underscores the need for real-world testing, such as strain gauge experiments, to validate simulation results and further optimize future designs for better performance and longevity. Finite Element Analysis (FEA) dozer blade stress distribution welding stresses design modifications fatigue resistance structural integrity manufacturing optimization Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 1. Introduction In today's globalized and competitive landscape, the design of construction and mining equipment is critical for enhancing efficiency and reducing operational costs. Among such equipment, excavators play a pivotal role due to their multifunctionality in earthmoving, digging, and material handling tasks. However, the components of these machines, including the dozer blade, are subjected to significant stresses and wear due to harsh working conditions. A robust and optimized design is therefore essential to ensure durability and cost-effectiveness. Welded steel structures, commonly found in excavator bodies and dozer blades, are particularly vulnerable to fatigue failures caused by stress concentrations at weld joints [ 1 ]. Such failures can reduce the lifespan of the structure and lead to fractures, potentially resulting in catastrophic failure [ 2 ]. To address these challenges, this study employs Finite Element Analysis (FEA) to evaluate the stress distribution and structural behavior of an excavator dozer blade under various loading conditions. The unpredictable nature of excavation sites demands highly reliable and resilient equipment. A key challenge for designers is to develop components that combine maximum reliability with lightweight and cost-effective solutions, all without compromising safety. This is especially critical for dozer blades, which must strike a balance between durability and operational efficiency [ 3 ]. Given their crucial role in construction and mining operations, optimizing the design of dozer blades is essential for ensuring reliable performance and extended service life. This study leverages FEA to assess stress distribution and structural integrity under various operational conditions, contributing to the development of improved designs. Historically, research on earthmoving machinery can be grouped into three main categories: kinematic studies, force analysis, and stress analysis. While many studies have focused on stress analyses of excavator booms, arms, and buckets, specific investigations on the stress analysis of dozer blades remain limited. Building on prior research, this study conducts a comprehensive FEA of an excavator dozer blade to assess stress distribution and strain behavior comprehensively. Earlier studies provide valuable insights into the design and analysis of dozer blades. For instance, J. Selech et al. [ 4 ] conducted strength analyses for dozer blades used in soil compactors, incorporating movable mechanisms to accommodate dynamic stresses. Although their FEM analysis revealed acceptable stress levels within Von Mises criteria, their boundary conditions were not clearly defined, leaving scope for further exploration. Similarly, Bhavesh Patel et al. [ 5 ] emphasized the versatility of FEM in designing hydraulic excavator attachments. However, limitations in material fatigue analyses and lifespan estimations were noted, which this study aims to address through advanced simulations and fatigue life assessments [ 6 ]. Other notable contributions include R.M. Dhawale et al. [ 8 ], who provided an overview of excavator attachments, focusing on efficiency and fuel consumption. Their research highlighted the importance of precise boundary conditions and problem-solving techniques. Dalgobind Mahto et al. [ 9 ] investigated stress distributions on the cutting edges of dozer blades using FEM-based elastic-plastic models, proposing new material applications such as austempered ductile iron (ADI). These insights are instrumental for validating experimental results and enhancing design optimization. The evolution of dozer blades traces its roots from primitive tools to modern hydraulic innovations. Notable developments, such as Samuel Pennock's "American Champion" in 1877, revolutionized excavation processes and laid the foundation for today’s advanced designs. Recent studies have explored the design of excavator mechanisms, such as Karagöz’s [ 10 ] work on three-dimensional semi-elliptic surface cracks in T-welded joints, leveraging sub-modeling and J-integral methods for stress and energy release rate calculations. Similarly, Patel et al. [ 11 ] conducted theoretical and experimental stress analyses to identify fatigue-prone regions, employing strain gauges and dynamic loading simulations to assess stress levels. Modern hydraulic systems have further enhanced dozer blade functionality, enabling precise grading, leveling, and backfilling. However, integrating dozer blades into excavators introduces challenges, particularly in ensuring durability under static and dynamic loads. This research addresses these challenges using FEM-based analysis and innovative design optimizations [ 15 ]. By synthesizing past findings and introducing novel methodologies, this study aims to advance heavy machinery design and provide practical solutions for future excavator applications. The primary objective of this study is to optimize the design of the HMK230LC model 23-ton excavator dozer blade using Finite Element Analysis (FEA). Through computational techniques, stress concentrations are identified, and the structural integrity of the blade under various loading conditions is evaluated. Geometry optimization is performed to refine the design, achieving weight reduction and improved manufacturability. By optimizing weld thickness, reducing sheet metal parts, and eliminating unnecessary bending processes, the study maintains strength while enhancing cost-efficiency. These efforts result in a lightweight, durable, and cost-effective design, contributing to the next generation of construction and mining equipment [ 16 ]. 2. MATERIAL AND METHOD The operation of an excavator dozer blade inherently involves repetitive and high-intensity tasks, subjecting all connection mechanisms to substantial forces. Without adequate control of these forces, the mechanisms risk failure, cracking, or a complete loss of functionality. Such failures lead to increased maintenance downtime, ultimately reducing the overall productivity and operational availability of the machine. Excavator mechanisms must perform reliably under unpredictable and challenging working conditions. Structural weaknesses in critical components, such as the dozer blade, blade mechanism, and lower chassis construction, can drastically shorten the excavator's lifespan. Therefore, these components must be robust enough to endure dynamic operational stresses. Given the variability of terrains, the static loads applied to the blade can differ significantly based on site conditions. Designing a dozer blade capable of operating reliably under diverse and unpredictable conditions, while withstanding all forces without failure, poses a considerable engineering challenge. Furthermore, achieving a lightweight design is essential for improving machine balance and energy efficiency, adding another layer of complexity to the design process [ 17 ]. During its operational cycle, the dozer blade must penetrate the ground, lift the machine, and perform grading tasks, all of which involve dynamic behavior and constant changes in position and orientation. To balance internal and external forces, varying torques must be applied at connection points. Internal forces arise from the movement of connections, including speed, acceleration, inertia, Coriolis effects, and friction, while external forces include environmental factors such as loads and gravity. Consequently, the connections and joints must be capable of withstanding the stresses generated by these forces and torques [ 18 ]. The new dozer blade design, developed specifically for Hidromek's HMK230LC excavator, addresses these challenges while prioritizing cost reduction and optimal functionality. These blades are primarily employed for grading, leveling terrain, and stabilizing the machine. The front dozer blade, designed as an auxiliary attachment for excavation and grading tasks, consists of several key components: the front blade, responsible for grading and leveling; the cylinder mount, which connects the blade to hydraulic cylinders and enables vertical movement; the lower chassis connection, which links the blade assembly to the excavator’s lower chassis and serves as a pivot point; the box profile, which provides structural rigidity between the blade and the machine connection points; and the stabilizing tube, which enhances resistance to torsional forces caused by lateral loads on the blade assembly [ 19 ]. The revised blade design simplifies the structure, reduces sheet thickness, and eliminates unnecessary bends to improve manufacturability and efficiency. For instance, the upper bend on the front grading sheet has been removed, reducing manufacturing time and labor requirements. Additionally, the "L" bend sheet at the back of the grading sheet has been integrated into the base sheet to form a "U" structure, thereby eliminating extra welding operations. The lower chassis connection has been redesigned to use a single sheet instead of welded assemblies, minimizing both welding and cutting operations. The box profile dimensions have been increased from 100x200x8 mm to 150x200x8 mm, significantly improving structural integrity and eliminating the need for additional side plates. The external radius of the box profile has also been reduced to enhance overall strength. These modifications collectively enhance manufacturability, reduce material usage, and improve the dozer blade’s structural performance under diverse operational conditions [ 19 ]. The excavator consists of two main groups: the upper group, which includes components such as the boom mechanism and turret, and the lower group, which comprises the hull. As illustrated in Fig. 1 , the position of the upper group relative to the lower group during grading, leveling terrain, and machine stabilization significantly affects the forces exerted on the dozer blade. Consequently, the strength analysis of the dozer blade must account for the position of the upper group. In this study, forces exerted on the dozer blade at the zero-degree position of the upper group are evaluated, and finite element analyses are conducted accordingly [ 20 ]. Figure 2 shows several positions of the upper group relative to the lower group. Using the finite element method, combined with geometry optimization and blade grading analysis, a three-dimensional optimized model has been developed. Tetrahedral solid elements are employed in the finite element mesh. The design is modeled using PTC Creo Parametric software and analyzed with MSC MARC/MENTAT finite element software [ 21 ]. Figure 3 provides a visualization of the excavator and its dozer blade model. The base material used for the grading sheet is Hardox, while other structural sheets are primarily made of ST-52 steel. The safe stress limit for the material is set at 235 MPa, which is 1.5 times below the yield strength of 355 MPa. For welded areas, the critical stress threshold is defined as 140 MPa. The present and the revised dozer blades are shown in Fig. 4 for comparison. The base material used for the grading sheet is Hardox, while other structural sheets are primarily made of ST-52 steel. The safe stress limit for the material is set at 235 MPa, which is 1.5 times below the yield strength of 355 MPa. For welded areas, the critical stress threshold is defined as 140 MPa. Figure 5 illustrates the forces acting on the blade while it is in contact with the ground during the weighing position. The hydraulic cylinder responsible for blade movement applies a force, "F." This force is calculated by taking moments around points "A" and "B," considering the weight centers of the upper group, lower group, and the attachment group. In the pre-processing stage of the finite element analysis, the geometric domain of the problem is first defined, and an appropriate element type is selected for the model. Material properties are then assigned to individual parts. The next step involves meshing, which is crucial for obtaining realistic results. The mesh size is chosen to be fine enough to capture variations within the domain but not excessively detailed, as that could increase computation time and introduce errors. Areas with high stress concentrations, such as welded connections, are meshed with a higher element density to improve solution accuracy. Boundary conditions are then defined, and loading conditions are applied to simulate real-world forces and inputs [ 22 ]. In this study, material behavior is assumed to be linear elastic, and strains are considered small. As a result, linear elastic analysis is performed. Static analysis is carried out to examine stress distributions at various points under a fixed load. Maximum principal stresses at welded regions are evaluated, with a safe stress threshold of 120 MPa. The Von Mises equivalent stress criterion is used to assess regional stresses in ductile materials. For ST-52 steel, the yield strength is taken as 355 MPa, and a safety factor of 1.5 is applied, resulting in a safe stress limit of 235 MPa. Variations across different design geometries are investigated to identify the optimal geometry, leading to a more cost-effective and practical design [ 23 ]. 3. RESULTS AND DISCUSSIONS The finite element analysis results for the dozer blade are presented in this section. To achieve accurate results, areas with higher stress gradients are refined and remeshed iteratively, as stress analyses are highly sensitive to mesh density. The Von Mises equivalent stress criterion is used to analyze regional stresses in ductile materials, while the maximum principal stress criterion is applied specifically to evaluate stresses in weld regions. The critical stress threshold for welded areas is set at 120 MPa to ensure safety [ 24 ]. Figure 6 illustrates the distribution of Von Mises stress, providing insights into the effects of combined loads on the material and helping to assess the design's strength limits. The highest stress areas, highlighted in red, indicate regions under significant stress. While the overall stress distribution remains below the allowable limits, these high-stress regions warrant careful analysis to prevent potential issues. Key critical areas include primary connection points, such as the attachment between the dozer blade and the frame, as well as corner regions that experience elevated stresses due to geometric stress concentrations. To mitigate the risk of fatigue, design improvements such as introducing radii or smoother transitions in sharp corners could be implemented [ 25 ]. The material's yield strength is directly compared with the calculated Von Mises stress values. If the highest stress exceeds the yield strength of the material, there is a risk of deformation or fracture. To enhance durability and reliability, design modifications may include increasing material thickness in high-stress regions, selecting higher-strength materials, optimizing geometry to reduce stress concentrations, or incorporating reinforcement elements such as plates or ribs near critical areas. The analysis also focused on regions where weld seams are present, with specific attention to maximum principal stresses. As shown in Fig. 7 , the stress distributions reveal notable stress concentrations at the welded joint between the box profile and the solid material connected by the end plate. These regions are identified as critical areas due to the high-stress gradients observed. In the dozer mechanism, the thickness of the end plate is a key factor influencing stress behavior at the weld regions. Reinforcing the end plate or increasing its thickness in these areas could significantly improve the structural integrity and reduce stress concentrations. It was observed that increasing the thickness of the end plate is expected to mitigate the bending effects in the critical regions, as shown in the exaggerated visualization in the provided figures. This adjustment would reduce the welding stresses and positively impact the structural integrity of the mechanism. To address these stress concentrations, reinforcing the critical stress zones with optimized weld designs or material reinforcements is recommended. Additionally, performing a detailed fatigue analysis will ensure long-term durability under cyclic loading conditions [ 26 ], [ 27 ]. To validate these recommendations, finite element analysis (FEA) simulations were rerun with updated parameters, including the increased thickness of the end plate. These findings highlight the importance of weld seam quality and structural modifications in reducing maximum stress levels and enhancing the overall performance and reliability of the dozer mechanism. The study predicts that increasing the thickness of the mirror sheet will reduce the bending effect observed in the region, as exaggeratedly depicted in Fig. 8 , leading to a positive impact on welding stress. After implementing the modifications, the dozer blade was re-analyzed under the same conditions, and the regional stresses were observed as shown in Fig. 9 and Fig. 10 . The analysis of Fig. 9 and Fig. 10 highlights critical insights into the stress distribution in the dozer blade mechanism. Figure 9 illustrates the distribution of the maximum principal stress, with stress values color-coded from low (dark blue) to high (red). The critical region of stress concentration is identified at 120 MPa, representing the maximum stress observed in the structure. The areas experiencing the highest stresses are primarily located near the connection points and welding zones of the mechanism, underscoring their significance in maintaining structural integrity. Stress concentration is particularly pronounced in regions with geometric changes, such as sharp corners, or where direct loads are applied. Modifications to the structure, specifically increasing the thickness of the mirror sheet, have reduced bending effects and improved load distribution. This adjustment resulted in a significant reduction in stress magnitude in critical regions, leading to a redistributed stress profile that enhances durability and resistance to mechanical fatigue, essential for high-stress applications like dozer mechanisms [ 28 ], [ 29 ]. Figure 10 focuses on the stress distribution within the welding zones, which are especially vulnerable due to material discontinuities and the heat-affected zone (HAZ). The maximum observed stress in these zones is again highlighted at 120 MPa, similar to the findings in Fig. 9 . Elevated stress levels are particularly evident at the junction between the main support and the blade arms, areas subjected to high bending and shear forces. This emphasizes the importance of welding quality and design in mitigating stress propagation and preventing structural failure. By increasing the thickness of the mirror sheet, the bending moments acting on the welding zones have been minimized, resulting in a more even stress distribution, as indicated by the broader spread of medium stress values (green to yellow areas) in the figure. These improvements significantly reduce the likelihood of stress-induced failures, such as crack initiation or propagation, within the welded connections [ 30 ]. In conclusion, the re-analysis after implementing the modifications demonstrates a marked reduction in localized stress concentrations and bending effects. The redesign effectively addresses the critical stress zones identified in earlier evaluations. Future recommendations include further optimization of welding techniques, such as post-weld heat treatments, and material selection to improve fatigue resistance and overall durability of the dozer blade mechanism. The overall stress distribution on the component remains within safe limits, consistent with the previous analysis, and noticeable improvements in welding stress were observed in the welding zones. The stress distribution under the applied boundary conditions is illustrated in Fig. 9 , while the maximum principal stress distribution Fig. 10 highlights areas of concentrated stress. To mitigate the welding stress at the joint between the box profile and the mirror sheet, the thickness of the mirror sheet was increased by 50%, resulting in a 14% reduction in welding stress, with the final stress levels falling within safe operational limits. Overall, the stress values measured on the raw materials of the dozer blade structure remain within safe and acceptable ranges. These findings confirm that the modifications to the mirror sheet thickness effectively reduced welding stresses while maintaining the structural integrity of the dozer blade under specified conditions [ 15 ]. When examining the overall structure of the dozer blade, the stress values measured on the raw materials are within safe limits. However, the analysis indicates that stress levels in some welding regions of certain parts are close to the limit values. This highlights the need for extra caution in the welded joints of these components. Any irregularity during manufacturing could lead to crack formation in the structure. Additionally, regions with localized stress concentrations should be validated through real-world testing. The location of the stress concentration should be confirmed using strain gauge experiments [ 29 ]. 4. CONCLUSIONS The Finite Element Analysis (FEA) performed on the HMK 230LC dozer blade provided significant insights into the structural behavior and stress distribution under various operational conditions. The analysis demonstrated that the maximum principal stress values and stress concentrations, particularly in welding zones and critical connection points, were crucial for assessing the structural integrity and durability of the mechanism.The results indicated that areas of highest stress, identified at 120 MPa, were concentrated around the connection points and welded joints, where geometric changes and direct loading are present. These regions were found to be critical to the structural performance of the dozer blade, necessitating design modifications to mitigate potential fatigue or failure risks. By increasing the thickness of the mirror sheet by 50%, a substantial reduction in bending effects was achieved, leading to improved load distribution and a 14% reduction in welding stresses at critical joints. This modification allowed the stress levels in the welding zones to remain well within safe operational limits, with the overall stress distribution across the dozer blade structure falling within acceptable ranges. The re-analysis after the design improvements confirmed that the localized stress concentrations and bending effects were significantly reduced. The increased thickness of the mirror sheet not only minimized welding stress but also enhanced the resistance to mechanical fatigue, which is essential for high-stress applications like dozer mechanisms. This adjustment also redistributed stresses more evenly, as evidenced by broader regions of medium stress levels in the post-modification stress analysis, effectively increasing the structural durability and reliability. The stress distribution in the welding zones, underscored the importance of high-quality welding and robust design in managing stress propagation. The findings showed that stresses at welded joints, particularly at the junctions between the main support and blade arms, were critical points requiring careful attention. By mitigating bending moments and ensuring a more even stress distribution, the likelihood of stress-induced failures, such as crack initiation and propagation, was significantly reduced. While the overall stress values across the raw materials of the dozer blade structure were found to be within safe limits, some welding regions approached critical stress thresholds, necessitating extra caution during manufacturing. Any irregularities in the welding process could lead to crack formation or structural weakness. To address these potential risks, the study recommends further optimizations, including the use of post-weld heat treatments, material reinforcements in high-stress areas, and the application of advanced welding techniques to enhance fatigue resistance. Moreover, the study highlights the need for validating simulation results through real-world testing. Strain gauge experiments should be conducted to confirm the location and magnitude of stress concentrations and ensure that the simulated boundary conditions accurately reflect operational realities. Additionally, regions with localized stress concentrations should be monitored for potential improvements in future designs, such as adding radii at sharp corners or optimizing geometries to further reduce stress intensities. In conclusion, the modifications to the mirror sheet thickness and subsequent design improvements effectively reduced welding stresses while maintaining the structural integrity of the dozer blade mechanism. The overall stress distribution remained within safe limits, ensuring reliable performance under specified conditions. Moving forward, continued validation, material optimization, and enhanced manufacturing processes will be critical in ensuring long-term durability and operational safety of the dozer blade. Declarations ACKNOWLEDGMENT This study was conducted as part of a university-industry collaboration, and we would like to express our sincere gratitude to Hidromek for their invaluable support. Their contributions in providing resources, expertise, and assistance with the analyses and design improvements were crucial to the success of this work Authors contribution DA, HÇ, and TD contributed to the preparation of this study. DA led the conceptualization and overall supervision of the project. HÇ conducted the finite element analyses and interpreted the results. TD supported the design modifications and drafting of the manuscript. All authors reviewed and approved the final version of the manuscript. All authors have read and approved the final version of the manuscript. Human Participants and/or Animals This study does not involve human participants or animals. Ethics Approval Ethics approval was not required for this study as it does not involve human participants, animal subjects, or any other activities requiring ethical oversight. Conflict of Interest and Authorship Conformation Form Please check the following as appropriate: All authors have participated in (a) conception and design, or analysis and interpretation of the data; (b) drafting the article or revising it critically for important intellectual content; and (c) approval of the final version. This manuscript has not been submitted to, nor is under review at, another journal or other publishing venue. The authors have no affiliation with any organization with a direct or indirect financial interest in the subject matter discussed in the manuscript The following authors have affiliations with organizations with direct or indirect financial interest in the subject matter discussed in the manuscript: Author’s name Affiliation Prof. Dr. Demiral AKBAR OSTIM Technical University Dr. Torga DURSUN aselsan Inc Microelectronics and Electro-Optics Harun ÇELİK OSTIM Technical University References Y. Chopra, P. Dahiya, and S. Kashyup, “Design and Analysis of a Dozer Blade.” . D. J. Thomas, “Analyzing the failure of welded steel components in construction systems,” J. Fail. Anal. Prev. , vol. 18, no. 2, pp. 304–314, Apr. 2018. “3. bir_kazici_yükleyic_makinenin.” . J. Selech et al. , “A working design of a bulldozer blade as additional equipment of a compaction drum roller,” MATEC Web Conf. , vol. 254, p. 04005, 2019. P. Patel and J. M. Prajapati, “A review on fea and optimization of backhoe attachment in hydraulic excavator,” IACSIT International Journal of Engineering and Technology , vol. 3, no. 5, pp. 505–511, 2011. O. Gölbaşi and N. Demirel, “Investigation of stress in an earthmover bucket using finite element analysis: A generic model for draglines,” J. S. Afr. Inst. Min. Metall. , vol. 115, no. 7, pp. 623–628, Jul. 2015. “5. Finite Element Analysis on Working Mechanism of Hydraulic Excavator.” . R. M. Dhawale and S. R. Wagh, “Finite element analysis of components of excavator arm- a review,” Int J Mech Eng & Rob Res , vol. 3, no. 2, pp. 1–7, 2014. D. Mahto and N. E. Mastorakis, Visualization of Strain influence on cutting edge of different Austempered Ductile Iron (ADI) products: FEA in Dozer Blade with ANSYS . 2016. T. Karagöz, A Finite Elements Based Approach For Fracture Analysis Of Welded Joints In Construction Machinery . 2007. S. H. Suryo, R. S. Sastra, Muchammad, and Harto, “Optimization of bucket tooth excavator design using topology optimization and finite element method,” J. Phys. Conf. Ser. , vol. 1858, no. 1, p. 012081, Apr. 2021. B. P. Patel and J. M. Prajapati, “An Excavation Force Calculations and Applications: An Analytical Approach,” International Journal of Engineering Science and Technology , vol. 3, no. 5, pp. 3831–3837, 2011. G. Kiper, C. C. Uzer, and M. Karabey, “Kineostatic Analysis and Arm Cylinder Design For An Excavator Arm Mechanism,” in 19. ULUSAL MAKİNA TEORİSİ SEMPOZYUMU , 2019. M. Yener, Design Of A Computer Interface For Automatic Finite Element Analysis Of An Excavator Boom . 2005. L. Pan et al. , “Fatigue analysis of dozer push arms under tilt bulldozing conditions,” Machines , vol. 10, no. 1, p. 38, Jan. 2022. Y.-S. Lee, S.-H. Kim, J. Seo, J. Han, and C.-S. Han, “Blade control in Cartesian space for leveling work by bulldozer,” Autom. Constr. , vol. 118, no. 103264, p. 103264, Oct. 2020. M. Doudkin, A. Kim, B. Aukenova, R. Radenkov, A. Saveliev, and N. Andryukhov, “Theoretical investigations of the process of interaction with the environment of a bulldozer bladow with variable geometry,” Istraz. Proj. Za Privredu , pp. 1–10, Jul. 2022. D. T, P. Y, and K. Y, “Study of forces acting on excavator bucket while digging,” J. Appl. Mech. Eng. , vol. 06, no. 05, 2017. Y. Z. Demi̇r and Y. Usta, “Kazıcı Yükleyici Makineler için Kazıcı Kepçe ile Çalışan Hidrolik Bir Çene Tasarımı ve Denenmesi,” Muş Alparslan Üniv. Fen Bilim. Derg. , vol. 7, no. 1, pp. 621–634, Jun. 2019. M. Z. Tekeste, T. R. Way, Z. Syed, and R. L. Schafer, “Modeling soil-bulldozer blade interaction using the discrete element method (DEM),” J. Terramech. , vol. 88, pp. 41–52, Apr. 2020. M. M. Cucos, I. M. Pista, and M. I. Ripanu, “Product engineering design enhancing by parameterizing the 3D solid model,” MATEC Web Conf. , vol. 178, p. 05011, 2018. M. S. Islam, F. Khan, and M. Hossain, “Vibration reduction of an excavator bucket using attachment technique,” Int. Rev. Mech. Eng. (IREME) , Jul. 2020. X. Zeng, J. Huo, H. Wang, Z. Wang, and M. Elchalakani, “Dynamic tensile behavior of steel HRB500E reinforcing bar at low, medium, and high strain rates,” Materials (Basel) , vol. 13, no. 1, p. 185, Jan. 2020. F. Uzun and A. M. Korsunsky, “Voxel‐based full‐field eigenstrain reconstruction of residual stresses,” Adv. Eng. Mater. , Apr. 2023. K. Bao, Q. Zhang, Y. Liu, and J. Dai, “Fatigue life of the welding seam of a tracked vehicle body structure evaluated using the structural stress method,” Eng. Fail. Anal. , vol. 120, no. 105102, p. 105102, Feb. 2021. Kirkhope KJ, Bell R, Caron L, Basu RI, Ma KT," Weld detail fatigue life improvement techniques. Part 1: review"Marine structures, vol.12, no.6, p. 447-474,1999. W. Rudorffer, M. Wächter, A. Esderts, F. Dittmann, and I. Varfolomeev, “Fatigue assessment of weld seams considering elastic–plastic material behavior using the local strain approach,” Weld. World , Jan. 2022. S. B. Wu and X. B. Liu, “Improvements for a hydraulic excavator’s boom,” Appl. Mech. Mater. , vol. 490–491, pp. 510–513, Jan. 2014. C. Yu, Y. Bao, and Q. Li, “Finite element analysis of excavator mechanical behavior and boom structure optimization,” Measurement (Lond.) , vol. 173, no. 108637, p. 108637, Mar. 2021. Z. Feng, N. Ma, S. Tsutsumi, and F. Lu, “Investigation of the residual stress in a multi-pass T-welded joint using low transformation temperature welding wire,” Materials (Basel) , vol. 14, no. 2, p. 325, Jan. 2021. Cite Share Download PDF Status: Published Journal Publication published 05 Jan, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Reviewers agreed at journal 18 Sep, 2025 Reviewers invited by journal 19 Mar, 2025 Editor assigned by journal 30 Jan, 2025 First submitted to journal 28 Jan, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-5915133","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":431182209,"identity":"745f02f2-00a8-4778-bd1a-7bbde749ac33","order_by":0,"name":"Demiral Akbar","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAABRElEQVRIie3SMUvDQBTA8VcC6eBru95RiV/hpFAsFvJVLIU6FdcIHS4EuhjqqlD8DClCZ8NBu9zZNWJBXZwUKkJRKOKZimhNnR3uT8IjBz94IQEwmf5jF+m1A4Conzx9W8tjJHqQ9YR8EqmnBTn+jbAsAl8k19UTlgTWkeL4qCG8DoFSqOLnw7O66+Y39m9ncrpJuRVfIywOVgiVKorliABRvSZVw1YjtAoD/yS5xzLYzV0EVuM/CUvaUcxtvcAEGfWHYg81CXAm0AGsljVZ3YzdPGryRmBrgpVXvy/clCxSUppnkqQQxX6XAFNhlfpc5D4WCyARejG0swiVejG/R3BbXrZqfKTfRRQGp6EUSAO7UuuzyiopjtX5E5/XHUe2xRXv1N38sYpmLyPhknFwlzx4zu8PswwzztLfYB0wmUwm01+9AyxqcvuldmLuAAAAAElFTkSuQmCC","orcid":"https://orcid.org/0000-0002-2102-1885","institution":"Ostim Technical University: OSTIM Teknik Universitesi","correspondingAuthor":true,"prefix":"","firstName":"Demiral","middleName":"","lastName":"Akbar","suffix":""},{"id":431182210,"identity":"ee8226a0-5df8-4129-86b5-afa105009801","order_by":1,"name":"Harun ÇELİK","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Harun","middleName":"","lastName":"ÇELİK","suffix":""},{"id":431182211,"identity":"39403411-fb57-431d-94b6-d508d52efe7a","order_by":2,"name":"Tolga DURSUN","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Tolga","middleName":"","lastName":"DURSUN","suffix":""}],"badges":[],"createdAt":"2025-01-27 21:55:56","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-5915133/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-5915133/v1","draftVersion":[],"editorialEvents":[{"content":"https://doi.org/10.1007/s00170-025-17256-2","type":"published","date":"2026-01-05T15:57:26+00:00"}],"editorialNote":"","failedWorkflow":false,"files":[{"id":79441327,"identity":"5f05b0de-3abb-4cc6-bb88-ca54e03bd907","added_by":"auto","created_at":"2025-03-28 12:59:52","extension":"png","order_by":1,"title":"Figure 1","display":"","copyAsset":false,"role":"figure","size":130910,"visible":true,"origin":"","legend":"\u003cp\u003eExcavator group components.\u003c/p\u003e","description":"","filename":"floatimage1.png","url":"https://assets-eu.researchsquare.com/files/rs-5915133/v1/6ca25b1b608a35772e0bedc3.png"},{"id":79440415,"identity":"f18d057b-9334-4f03-86aa-0a87bccee9ca","added_by":"auto","created_at":"2025-03-28 12:51:52","extension":"png","order_by":2,"title":"Figure 2","display":"","copyAsset":false,"role":"figure","size":12704,"visible":true,"origin":"","legend":"\u003cp\u003eUpper group alignment relative to lower group, a) 0°, b) 45°, c) 90°.\u003c/p\u003e","description":"","filename":"floatimage2.png","url":"https://assets-eu.researchsquare.com/files/rs-5915133/v1/60d0866924e24d16ab40a687.png"},{"id":79440426,"identity":"a155535e-7050-4698-96a0-509b127cfa32","added_by":"auto","created_at":"2025-03-28 12:51:52","extension":"png","order_by":3,"title":"Figure 3","display":"","copyAsset":false,"role":"figure","size":78018,"visible":true,"origin":"","legend":"\u003cp\u003eExcavator and dozer blade.\u003c/p\u003e","description":"","filename":"floatimage3.png","url":"https://assets-eu.researchsquare.com/files/rs-5915133/v1/8d26c550e13d7de8c7f4749c.png"},{"id":79441328,"identity":"d30dba7c-11ea-4326-9571-3b442077db05","added_by":"auto","created_at":"2025-03-28 12:59:52","extension":"png","order_by":4,"title":"Figure 4","display":"","copyAsset":false,"role":"figure","size":124536,"visible":true,"origin":"","legend":"\u003cp\u003ePresent and revised models of dozer blade.\u003c/p\u003e","description":"","filename":"floatimage4.png","url":"https://assets-eu.researchsquare.com/files/rs-5915133/v1/cadf0f4947abb84b3642816e.png"},{"id":79440433,"identity":"bf24ebcc-795c-4822-b470-2e35d40e8d23","added_by":"auto","created_at":"2025-03-28 12:51:52","extension":"png","order_by":5,"title":"Figure 5","display":"","copyAsset":false,"role":"figure","size":54613,"visible":true,"origin":"","legend":"\u003cp\u003eLoads acting on the dozer mechanism.\u003c/p\u003e","description":"","filename":"floatimage5.png","url":"https://assets-eu.researchsquare.com/files/rs-5915133/v1/8f5b8918b652bfcdd2490640.png"},{"id":79441329,"identity":"d7de2824-6614-478b-88d6-7b2f27907047","added_by":"auto","created_at":"2025-03-28 12:59:52","extension":"jpg","order_by":6,"title":"Figure 6","display":"","copyAsset":false,"role":"figure","size":30615,"visible":true,"origin":"","legend":"\u003cp\u003eVon Mises equivalent stress distribution (MPa) in dozer blade.\u003c/p\u003e","description":"","filename":"6.jpg","url":"https://assets-eu.researchsquare.com/files/rs-5915133/v1/c13be3d6d927e2e21298196e.jpg"},{"id":79441333,"identity":"d5f20c73-674b-47e0-8c2f-1752f471ddaa","added_by":"auto","created_at":"2025-03-28 12:59:52","extension":"png","order_by":7,"title":"Figure 7","display":"","copyAsset":false,"role":"figure","size":190379,"visible":true,"origin":"","legend":"\u003cp\u003eMaximum principal stress distribution in the welded regions of the dozer mechanism.\u003c/p\u003e","description":"","filename":"floatimage7.png","url":"https://assets-eu.researchsquare.com/files/rs-5915133/v1/e171120f708d1c923a351056.png"},{"id":79440422,"identity":"2f7e4484-c62e-4485-9d4b-54e49184c8a0","added_by":"auto","created_at":"2025-03-28 12:51:52","extension":"jpg","order_by":8,"title":"Figure 8","display":"","copyAsset":false,"role":"figure","size":14279,"visible":true,"origin":"","legend":"\u003cp\u003e300X exaggerated visualization of the box profile-mirror sheet joint in the dozer blade.\u003c/p\u003e","description":"","filename":"8.jpg","url":"https://assets-eu.researchsquare.com/files/rs-5915133/v1/7a5b7b479c44307bde77f2b3.jpg"},{"id":79441667,"identity":"116a094a-f045-4b5a-ab2d-3fe09aaf55f5","added_by":"auto","created_at":"2025-03-28 13:07:52","extension":"png","order_by":9,"title":"Figure 9","display":"","copyAsset":false,"role":"figure","size":104157,"visible":true,"origin":"","legend":"\u003cp\u003eStress distribution in the dozer mechanism with increased thickness.\u003c/p\u003e","description":"","filename":"floatimage9.png","url":"https://assets-eu.researchsquare.com/files/rs-5915133/v1/ce767378e8ca48f6ed9da237.png"},{"id":79440428,"identity":"aae67f26-11ee-4cc5-83d6-0a12f4e12c71","added_by":"auto","created_at":"2025-03-28 12:51:52","extension":"png","order_by":10,"title":"Figure 10","display":"","copyAsset":false,"role":"figure","size":163796,"visible":true,"origin":"","legend":"\u003cp\u003eStress Distribution in the Welding Zones of the Dozer Mechanism with increased thickness.\u003c/p\u003e","description":"","filename":"floatimage10.png","url":"https://assets-eu.researchsquare.com/files/rs-5915133/v1/659d51f1e6917ef07b9fc9bc.png"},{"id":100069095,"identity":"8501f6b6-2a0f-4272-be1a-0ce6546cd108","added_by":"auto","created_at":"2026-01-12 16:09:12","extension":"pdf","order_by":0,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1289272,"visible":true,"origin":"","legend":"","description":"","filename":"manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-5915133/v1/fb3cc763-9a79-45c8-8ba8-5e436ba6573b.pdf"}],"financialInterests":"","formattedTitle":"Optimization of an Excavator Dozer Blade Using the Finite Element Method: Evaluating Upper Group Alignment at Zero Degrees to the Lower Group","fulltext":[{"header":"1. Introduction","content":"\u003cp\u003eIn today's globalized and competitive landscape, the design of construction and mining equipment is critical for enhancing efficiency and reducing operational costs. Among such equipment, excavators play a pivotal role due to their multifunctionality in earthmoving, digging, and material handling tasks. However, the components of these machines, including the dozer blade, are subjected to significant stresses and wear due to harsh working conditions. A robust and optimized design is therefore essential to ensure durability and cost-effectiveness. Welded steel structures, commonly found in excavator bodies and dozer blades, are particularly vulnerable to fatigue failures caused by stress concentrations at weld joints [\u003cspan citationid=\"CR1\" class=\"CitationRef\"\u003e1\u003c/span\u003e]. Such failures can reduce the lifespan of the structure and lead to fractures, potentially resulting in catastrophic failure [\u003cspan citationid=\"CR2\" class=\"CitationRef\"\u003e2\u003c/span\u003e]. To address these challenges, this study employs Finite Element Analysis (FEA) to evaluate the stress distribution and structural behavior of an excavator dozer blade under various loading conditions.\u003c/p\u003e \u003cp\u003eThe unpredictable nature of excavation sites demands highly reliable and resilient equipment. A key challenge for designers is to develop components that combine maximum reliability with lightweight and cost-effective solutions, all without compromising safety. This is especially critical for dozer blades, which must strike a balance between durability and operational efficiency [\u003cspan citationid=\"CR3\" class=\"CitationRef\"\u003e3\u003c/span\u003e]. Given their crucial role in construction and mining operations, optimizing the design of dozer blades is essential for ensuring reliable performance and extended service life. This study leverages FEA to assess stress distribution and structural integrity under various operational conditions, contributing to the development of improved designs.\u003c/p\u003e \u003cp\u003eHistorically, research on earthmoving machinery can be grouped into three main categories: kinematic studies, force analysis, and stress analysis. While many studies have focused on stress analyses of excavator booms, arms, and buckets, specific investigations on the stress analysis of dozer blades remain limited. Building on prior research, this study conducts a comprehensive FEA of an excavator dozer blade to assess stress distribution and strain behavior comprehensively.\u003c/p\u003e \u003cp\u003eEarlier studies provide valuable insights into the design and analysis of dozer blades. For instance, J. Selech et al. [\u003cspan citationid=\"CR4\" class=\"CitationRef\"\u003e4\u003c/span\u003e] conducted strength analyses for dozer blades used in soil compactors, incorporating movable mechanisms to accommodate dynamic stresses. Although their FEM analysis revealed acceptable stress levels within Von Mises criteria, their boundary conditions were not clearly defined, leaving scope for further exploration. Similarly, Bhavesh Patel et al. [\u003cspan citationid=\"CR5\" class=\"CitationRef\"\u003e5\u003c/span\u003e] emphasized the versatility of FEM in designing hydraulic excavator attachments. However, limitations in material fatigue analyses and lifespan estimations were noted, which this study aims to address through advanced simulations and fatigue life assessments [\u003cspan citationid=\"CR6\" class=\"CitationRef\"\u003e6\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eOther notable contributions include R.M. Dhawale et al. [\u003cspan citationid=\"CR8\" class=\"CitationRef\"\u003e8\u003c/span\u003e], who provided an overview of excavator attachments, focusing on efficiency and fuel consumption. Their research highlighted the importance of precise boundary conditions and problem-solving techniques. Dalgobind Mahto et al. [\u003cspan citationid=\"CR9\" class=\"CitationRef\"\u003e9\u003c/span\u003e] investigated stress distributions on the cutting edges of dozer blades using FEM-based elastic-plastic models, proposing new material applications such as austempered ductile iron (ADI). These insights are instrumental for validating experimental results and enhancing design optimization.\u003c/p\u003e \u003cp\u003eThe evolution of dozer blades traces its roots from primitive tools to modern hydraulic innovations. Notable developments, such as Samuel Pennock's \"American Champion\" in 1877, revolutionized excavation processes and laid the foundation for today\u0026rsquo;s advanced designs. Recent studies have explored the design of excavator mechanisms, such as Karag\u0026ouml;z\u0026rsquo;s [\u003cspan citationid=\"CR10\" class=\"CitationRef\"\u003e10\u003c/span\u003e] work on three-dimensional semi-elliptic surface cracks in T-welded joints, leveraging sub-modeling and J-integral methods for stress and energy release rate calculations. Similarly, Patel et al. [\u003cspan citationid=\"CR11\" class=\"CitationRef\"\u003e11\u003c/span\u003e] conducted theoretical and experimental stress analyses to identify fatigue-prone regions, employing strain gauges and dynamic loading simulations to assess stress levels.\u003c/p\u003e \u003cp\u003eModern hydraulic systems have further enhanced dozer blade functionality, enabling precise grading, leveling, and backfilling. However, integrating dozer blades into excavators introduces challenges, particularly in ensuring durability under static and dynamic loads. This research addresses these challenges using FEM-based analysis and innovative design optimizations [\u003cspan citationid=\"CR15\" class=\"CitationRef\"\u003e15\u003c/span\u003e]. By synthesizing past findings and introducing novel methodologies, this study aims to advance heavy machinery design and provide practical solutions for future excavator applications.\u003c/p\u003e \u003cp\u003eThe primary objective of this study is to optimize the design of the HMK230LC model 23-ton excavator dozer blade using Finite Element Analysis (FEA). Through computational techniques, stress concentrations are identified, and the structural integrity of the blade under various loading conditions is evaluated. Geometry optimization is performed to refine the design, achieving weight reduction and improved manufacturability. By optimizing weld thickness, reducing sheet metal parts, and eliminating unnecessary bending processes, the study maintains strength while enhancing cost-efficiency. These efforts result in a lightweight, durable, and cost-effective design, contributing to the next generation of construction and mining equipment [\u003cspan citationid=\"CR16\" class=\"CitationRef\"\u003e16\u003c/span\u003e].\u003c/p\u003e"},{"header":"2. MATERIAL AND METHOD","content":"\u003cp\u003eThe operation of an excavator dozer blade inherently involves repetitive and high-intensity tasks, subjecting all connection mechanisms to substantial forces. Without adequate control of these forces, the mechanisms risk failure, cracking, or a complete loss of functionality. Such failures lead to increased maintenance downtime, ultimately reducing the overall productivity and operational availability of the machine. Excavator mechanisms must perform reliably under unpredictable and challenging working conditions. Structural weaknesses in critical components, such as the dozer blade, blade mechanism, and lower chassis construction, can drastically shorten the excavator's lifespan. Therefore, these components must be robust enough to endure dynamic operational stresses. Given the variability of terrains, the static loads applied to the blade can differ significantly based on site conditions. Designing a dozer blade capable of operating reliably under diverse and unpredictable conditions, while withstanding all forces without failure, poses a considerable engineering challenge. Furthermore, achieving a lightweight design is essential for improving machine balance and energy efficiency, adding another layer of complexity to the design process [\u003cspan citationid=\"CR17\" class=\"CitationRef\"\u003e17\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eDuring its operational cycle, the dozer blade must penetrate the ground, lift the machine, and perform grading tasks, all of which involve dynamic behavior and constant changes in position and orientation. To balance internal and external forces, varying torques must be applied at connection points. Internal forces arise from the movement of connections, including speed, acceleration, inertia, Coriolis effects, and friction, while external forces include environmental factors such as loads and gravity. Consequently, the connections and joints must be capable of withstanding the stresses generated by these forces and torques [\u003cspan citationid=\"CR18\" class=\"CitationRef\"\u003e18\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eThe new dozer blade design, developed specifically for Hidromek's HMK230LC excavator, addresses these challenges while prioritizing cost reduction and optimal functionality. These blades are primarily employed for grading, leveling terrain, and stabilizing the machine. The front dozer blade, designed as an auxiliary attachment for excavation and grading tasks, consists of several key components: the front blade, responsible for grading and leveling; the cylinder mount, which connects the blade to hydraulic cylinders and enables vertical movement; the lower chassis connection, which links the blade assembly to the excavator\u0026rsquo;s lower chassis and serves as a pivot point; the box profile, which provides structural rigidity between the blade and the machine connection points; and the stabilizing tube, which enhances resistance to torsional forces caused by lateral loads on the blade assembly [\u003cspan citationid=\"CR19\" class=\"CitationRef\"\u003e19\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eThe revised blade design simplifies the structure, reduces sheet thickness, and eliminates unnecessary bends to improve manufacturability and efficiency. For instance, the upper bend on the front grading sheet has been removed, reducing manufacturing time and labor requirements. Additionally, the \"L\" bend sheet at the back of the grading sheet has been integrated into the base sheet to form a \"U\" structure, thereby eliminating extra welding operations. The lower chassis connection has been redesigned to use a single sheet instead of welded assemblies, minimizing both welding and cutting operations. The box profile dimensions have been increased from 100x200x8 mm to 150x200x8 mm, significantly improving structural integrity and eliminating the need for additional side plates. The external radius of the box profile has also been reduced to enhance overall strength. These modifications collectively enhance manufacturability, reduce material usage, and improve the dozer blade\u0026rsquo;s structural performance under diverse operational conditions [\u003cspan citationid=\"CR19\" class=\"CitationRef\"\u003e19\u003c/span\u003e].\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eThe excavator consists of two main groups: the upper group, which includes components such as the boom mechanism and turret, and the lower group, which comprises the hull. As illustrated in Fig.\u0026nbsp;\u003cspan refid=\"Fig1\" class=\"InternalRef\"\u003e1\u003c/span\u003e, the position of the upper group relative to the lower group during grading, leveling terrain, and machine stabilization significantly affects the forces exerted on the dozer blade. Consequently, the strength analysis of the dozer blade must account for the position of the upper group. In this study, forces exerted on the dozer blade at the zero-degree position of the upper group are evaluated, and finite element analyses are conducted accordingly [\u003cspan citationid=\"CR20\" class=\"CitationRef\"\u003e20\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eFigure \u003cspan refid=\"Fig2\" class=\"InternalRef\"\u003e2\u003c/span\u003e shows several positions of the upper group relative to the lower group.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eUsing the finite element method, combined with geometry optimization and blade grading analysis, a three-dimensional optimized model has been developed. Tetrahedral solid elements are employed in the finite element mesh. The design is modeled using PTC Creo Parametric software and analyzed with MSC MARC/MENTAT finite element software [\u003cspan citationid=\"CR21\" class=\"CitationRef\"\u003e21\u003c/span\u003e]. Figure\u0026nbsp;\u003cspan refid=\"Fig3\" class=\"InternalRef\"\u003e3\u003c/span\u003e provides a visualization of the excavator and its dozer blade model.\u003c/p\u003e \u003cp\u003eThe base material used for the grading sheet is Hardox, while other structural sheets are primarily made of ST-52 steel. The safe stress limit for the material is set at 235 MPa, which is 1.5 times below the yield strength of 355 MPa. For welded areas, the critical stress threshold is defined as 140 MPa.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eThe present and the revised dozer blades are shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig4\" class=\"InternalRef\"\u003e4\u003c/span\u003e for comparison.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eThe base material used for the grading sheet is Hardox, while other structural sheets are primarily made of ST-52 steel. The safe stress limit for the material is set at 235 MPa, which is 1.5 times below the yield strength of 355 MPa. For welded areas, the critical stress threshold is defined as 140 MPa. Figure\u0026nbsp;\u003cspan refid=\"Fig5\" class=\"InternalRef\"\u003e5\u003c/span\u003e illustrates the forces acting on the blade while it is in contact with the ground during the weighing position. The hydraulic cylinder responsible for blade movement applies a force, \"F.\" This force is calculated by taking moments around points \"A\" and \"B,\" considering the weight centers of the upper group, lower group, and the attachment group.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eIn the pre-processing stage of the finite element analysis, the geometric domain of the problem is first defined, and an appropriate element type is selected for the model. Material properties are then assigned to individual parts. The next step involves meshing, which is crucial for obtaining realistic results. The mesh size is chosen to be fine enough to capture variations within the domain but not excessively detailed, as that could increase computation time and introduce errors. Areas with high stress concentrations, such as welded connections, are meshed with a higher element density to improve solution accuracy. Boundary conditions are then defined, and loading conditions are applied to simulate real-world forces and inputs [\u003cspan citationid=\"CR22\" class=\"CitationRef\"\u003e22\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eIn this study, material behavior is assumed to be linear elastic, and strains are considered small. As a result, linear elastic analysis is performed. Static analysis is carried out to examine stress distributions at various points under a fixed load. Maximum principal stresses at welded regions are evaluated, with a safe stress threshold of 120 MPa. The Von Mises equivalent stress criterion is used to assess regional stresses in ductile materials. For ST-52 steel, the yield strength is taken as 355 MPa, and a safety factor of 1.5 is applied, resulting in a safe stress limit of 235 MPa. Variations across different design geometries are investigated to identify the optimal geometry, leading to a more cost-effective and practical design [\u003cspan citationid=\"CR23\" class=\"CitationRef\"\u003e23\u003c/span\u003e].\u003c/p\u003e"},{"header":"3. RESULTS AND DISCUSSIONS","content":"\u003cp\u003eThe finite element analysis results for the dozer blade are presented in this section. To achieve accurate results, areas with higher stress gradients are refined and remeshed iteratively, as stress analyses are highly sensitive to mesh density. The Von Mises equivalent stress criterion is used to analyze regional stresses in ductile materials, while the maximum principal stress criterion is applied specifically to evaluate stresses in weld regions. The critical stress threshold for welded areas is set at 120 MPa to ensure safety [\u003cspan citationid=\"CR24\" class=\"CitationRef\"\u003e24\u003c/span\u003e]. Figure\u0026nbsp;6 illustrates the distribution of Von Mises stress, providing insights into the effects of combined loads on the material and helping to assess the design's strength limits. The highest stress areas, highlighted in red, indicate regions under significant stress. While the overall stress distribution remains below the allowable limits, these high-stress regions warrant careful analysis to prevent potential issues.\u003c/p\u003e \u003cp\u003e Key critical areas include primary connection points, such as the attachment between the dozer blade and the frame, as well as corner regions that experience elevated stresses due to geometric stress concentrations. To mitigate the risk of fatigue, design improvements such as introducing radii or smoother transitions in sharp corners could be implemented [\u003cspan citationid=\"CR25\" class=\"CitationRef\"\u003e25\u003c/span\u003e]. The material's yield strength is directly compared with the calculated Von Mises stress values. If the highest stress exceeds the yield strength of the material, there is a risk of deformation or fracture. To enhance durability and reliability, design modifications may include increasing material thickness in high-stress regions, selecting higher-strength materials, optimizing geometry to reduce stress concentrations, or incorporating reinforcement elements such as plates or ribs near critical areas.\u003c/p\u003e \u003cp\u003eThe analysis also focused on regions where weld seams are present, with specific attention to maximum principal stresses. As shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig6\" class=\"InternalRef\"\u003e7\u003c/span\u003e, the stress distributions reveal notable stress concentrations at the welded joint between the box profile and the solid material connected by the end plate. These regions are identified as critical areas due to the high-stress gradients observed. In the dozer mechanism, the thickness of the end plate is a key factor influencing stress behavior at the weld regions. Reinforcing the end plate or increasing its thickness in these areas could significantly improve the structural integrity and reduce stress concentrations.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eIt was observed that increasing the thickness of the end plate is expected to mitigate the bending effects in the critical regions, as shown in the exaggerated visualization in the provided figures. This adjustment would reduce the welding stresses and positively impact the structural integrity of the mechanism. To address these stress concentrations, reinforcing the critical stress zones with optimized weld designs or material reinforcements is recommended. Additionally, performing a detailed fatigue analysis will ensure long-term durability under cyclic loading conditions [\u003cspan citationid=\"CR26\" class=\"CitationRef\"\u003e26\u003c/span\u003e], [\u003cspan citationid=\"CR27\" class=\"CitationRef\"\u003e27\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eTo validate these recommendations, finite element analysis (FEA) simulations were rerun with updated parameters, including the increased thickness of the end plate. These findings highlight the importance of weld seam quality and structural modifications in reducing maximum stress levels and enhancing the overall performance and reliability of the dozer mechanism.\u003c/p\u003e \u003cp\u003eThe study predicts that increasing the thickness of the mirror sheet will reduce the bending effect observed in the region, as exaggeratedly depicted in Fig.\u0026nbsp;\u003cspan refid=\"Fig7\" class=\"InternalRef\"\u003e8\u003c/span\u003e, leading to a positive impact on welding stress. After implementing the modifications, the dozer blade was re-analyzed under the same conditions, and the regional stresses were observed as shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig8\" class=\"InternalRef\"\u003e9\u003c/span\u003e and Fig.\u0026nbsp;\u003cspan refid=\"Fig9\" class=\"InternalRef\"\u003e10\u003c/span\u003e.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eThe analysis of Fig.\u0026nbsp;\u003cspan refid=\"Fig8\" class=\"InternalRef\"\u003e9\u003c/span\u003e and Fig.\u0026nbsp;\u003cspan refid=\"Fig9\" class=\"InternalRef\"\u003e10\u003c/span\u003e highlights critical insights into the stress distribution in the dozer blade mechanism. Figure\u0026nbsp;\u003cspan refid=\"Fig8\" class=\"InternalRef\"\u003e9\u003c/span\u003e illustrates the distribution of the maximum principal stress, with stress values color-coded from low (dark blue) to high (red). The critical region of stress concentration is identified at 120 MPa, representing the maximum stress observed in the structure. The areas experiencing the highest stresses are primarily located near the connection points and welding zones of the mechanism, underscoring their significance in maintaining structural integrity. Stress concentration is particularly pronounced in regions with geometric changes, such as sharp corners, or where direct loads are applied. Modifications to the structure, specifically increasing the thickness of the mirror sheet, have reduced bending effects and improved load distribution. This adjustment resulted in a significant reduction in stress magnitude in critical regions, leading to a redistributed stress profile that enhances durability and resistance to mechanical fatigue, essential for high-stress applications like dozer mechanisms [\u003cspan citationid=\"CR28\" class=\"CitationRef\"\u003e28\u003c/span\u003e], [\u003cspan citationid=\"CR29\" class=\"CitationRef\"\u003e29\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eFigure \u003cspan refid=\"Fig9\" class=\"InternalRef\"\u003e10\u003c/span\u003e focuses on the stress distribution within the welding zones, which are especially vulnerable due to material discontinuities and the heat-affected zone (HAZ). The maximum observed stress in these zones is again highlighted at 120 MPa, similar to the findings in Fig.\u0026nbsp;\u003cspan refid=\"Fig8\" class=\"InternalRef\"\u003e9\u003c/span\u003e. Elevated stress levels are particularly evident at the junction between the main support and the blade arms, areas subjected to high bending and shear forces. This emphasizes the importance of welding quality and design in mitigating stress propagation and preventing structural failure. By increasing the thickness of the mirror sheet, the bending moments acting on the welding zones have been minimized, resulting in a more even stress distribution, as indicated by the broader spread of medium stress values (green to yellow areas) in the figure. These improvements significantly reduce the likelihood of stress-induced failures, such as crack initiation or propagation, within the welded connections [\u003cspan citationid=\"CR30\" class=\"CitationRef\"\u003e30\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eIn conclusion, the re-analysis after implementing the modifications demonstrates a marked reduction in localized stress concentrations and bending effects. The redesign effectively addresses the critical stress zones identified in earlier evaluations. Future recommendations include further optimization of welding techniques, such as post-weld heat treatments, and material selection to improve fatigue resistance and overall durability of the dozer blade mechanism.\u003c/p\u003e \u003cp\u003eThe overall stress distribution on the component remains within safe limits, consistent with the previous analysis, and noticeable improvements in welding stress were observed in the welding zones. The stress distribution under the applied boundary conditions is illustrated in Fig.\u0026nbsp;\u003cspan refid=\"Fig8\" class=\"InternalRef\"\u003e9\u003c/span\u003e, while the maximum principal stress distribution Fig.\u0026nbsp;\u003cspan refid=\"Fig9\" class=\"InternalRef\"\u003e10\u003c/span\u003e highlights areas of concentrated stress. To mitigate the welding stress at the joint between the box profile and the mirror sheet, the thickness of the mirror sheet was increased by 50%, resulting in a 14% reduction in welding stress, with the final stress levels falling within safe operational limits. Overall, the stress values measured on the raw materials of the dozer blade structure remain within safe and acceptable ranges. These findings confirm that the modifications to the mirror sheet thickness effectively reduced welding stresses while maintaining the structural integrity of the dozer blade under specified conditions [\u003cspan citationid=\"CR15\" class=\"CitationRef\"\u003e15\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eWhen examining the overall structure of the dozer blade, the stress values measured on the raw materials are within safe limits. However, the analysis indicates that stress levels in some welding regions of certain parts are close to the limit values. This highlights the need for extra caution in the welded joints of these components. Any irregularity during manufacturing could lead to crack formation in the structure. Additionally, regions with localized stress concentrations should be validated through real-world testing. The location of the stress concentration should be confirmed using strain gauge experiments [\u003cspan citationid=\"CR29\" class=\"CitationRef\"\u003e29\u003c/span\u003e].\u003c/p\u003e"},{"header":"4. CONCLUSIONS","content":"\u003cp\u003eThe Finite Element Analysis (FEA) performed on the HMK 230LC dozer blade provided significant insights into the structural behavior and stress distribution under various operational conditions. The analysis demonstrated that the maximum principal stress values and stress concentrations, particularly in welding zones and critical connection points, were crucial for assessing the structural integrity and durability of the mechanism.The results indicated that areas of highest stress, identified at 120 MPa, were concentrated around the connection points and welded joints, where geometric changes and direct loading are present. These regions were found to be critical to the structural performance of the dozer blade, necessitating design modifications to mitigate potential fatigue or failure risks. By increasing the thickness of the mirror sheet by 50%, a substantial reduction in bending effects was achieved, leading to improved load distribution and a 14% reduction in welding stresses at critical joints. This modification allowed the stress levels in the welding zones to remain well within safe operational limits, with the overall stress distribution across the dozer blade structure falling within acceptable ranges.\u003c/p\u003e \u003cp\u003eThe re-analysis after the design improvements confirmed that the localized stress concentrations and bending effects were significantly reduced. The increased thickness of the mirror sheet not only minimized welding stress but also enhanced the resistance to mechanical fatigue, which is essential for high-stress applications like dozer mechanisms. This adjustment also redistributed stresses more evenly, as evidenced by broader regions of medium stress levels in the post-modification stress analysis, effectively increasing the structural durability and reliability. The stress distribution in the welding zones, underscored the importance of high-quality welding and robust design in managing stress propagation. The findings showed that stresses at welded joints, particularly at the junctions between the main support and blade arms, were critical points requiring careful attention. By mitigating bending moments and ensuring a more even stress distribution, the likelihood of stress-induced failures, such as crack initiation and propagation, was significantly reduced.\u003c/p\u003e \u003cp\u003eWhile the overall stress values across the raw materials of the dozer blade structure were found to be within safe limits, some welding regions approached critical stress thresholds, necessitating extra caution during manufacturing. Any irregularities in the welding process could lead to crack formation or structural weakness. To address these potential risks, the study recommends further optimizations, including the use of post-weld heat treatments, material reinforcements in high-stress areas, and the application of advanced welding techniques to enhance fatigue resistance.\u003c/p\u003e \u003cp\u003eMoreover, the study highlights the need for validating simulation results through real-world testing. Strain gauge experiments should be conducted to confirm the location and magnitude of stress concentrations and ensure that the simulated boundary conditions accurately reflect operational realities. Additionally, regions with localized stress concentrations should be monitored for potential improvements in future designs, such as adding radii at sharp corners or optimizing geometries to further reduce stress intensities.\u003c/p\u003e \u003cp\u003eIn conclusion, the modifications to the mirror sheet thickness and subsequent design improvements effectively reduced welding stresses while maintaining the structural integrity of the dozer blade mechanism. The overall stress distribution remained within safe limits, ensuring reliable performance under specified conditions. Moving forward, continued validation, material optimization, and enhanced manufacturing processes will be critical in ensuring long-term durability and operational safety of the dozer blade.\u003c/p\u003e"},{"header":"Declarations","content":"\u003cp\u003e\u003cstrong\u003eACKNOWLEDGMENT\u0026nbsp;\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eThis study was conducted as part of a university-industry collaboration, and we would like to express our sincere gratitude to Hidromek for their invaluable support. Their contributions in providing resources, expertise, and assistance with the analyses and design improvements were crucial to the success of this work\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eAuthors contribution\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eDA, H\u0026Ccedil;, and TD contributed to the preparation of this study. DA led the conceptualization and overall supervision of the project. H\u0026Ccedil; conducted the finite element analyses and interpreted the results. TD supported the design modifications and drafting of the manuscript. All authors reviewed and approved the final version of the manuscript.\u003c/p\u003e\n\u003cp\u003eAll authors have read and approved the final version of the manuscript.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eHuman Participants and/or Animals\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eThis study does not involve human participants or animals.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eEthics Approval\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eEthics approval was not required for this study as it does not involve human participants, animal subjects, or any other activities requiring ethical oversight.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eConflict of Interest and Authorship Conformation Form\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003ePlease check the following as appropriate:\u003c/p\u003e\n\u003cul\u003e\n \u003cli\u003eAll authors have participated in (a) conception and design, or analysis and interpretation of the data; (b) drafting the article or revising it critically for important intellectual content; and (c) approval of the final version.\u003c/li\u003e\n \u003cli\u003eThis manuscript has not been submitted to, nor is under review at, another journal or other publishing venue.\u003c/li\u003e\n \u003cli\u003eThe authors have no affiliation with any organization with a direct or indirect financial interest in the subject matter discussed in the manuscript\u003c/li\u003e\n \u003cli\u003eThe following authors have affiliations with organizations with direct or indirect financial interest in the subject matter discussed in the manuscript:\u003c/li\u003e\n\u003c/ul\u003e\n\u003cp\u003eAuthor\u0026rsquo;s name Affiliation\u003c/p\u003e\n\u003cp\u003eProf. Dr. Demiral AKBAR\u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; OSTIM Technical University\u003c/p\u003e\n\u003cp\u003eDr. Torga DURSUN\u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp;aselsan Inc Microelectronics and Electro-Optics\u003c/p\u003e\n\u003cp\u003eHarun \u0026Ccedil;ELİK\u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; \u0026nbsp; OSTIM Technical University\u003c/p\u003e"},{"header":"References","content":"\u003col\u003e\n\u003cli\u003eY. Chopra, P. Dahiya, and S. Kashyup, \u0026ldquo;Design and Analysis of a Dozer Blade.\u0026rdquo; .\u003c/li\u003e\n\u003cli\u003eD. J. Thomas, \u0026ldquo;Analyzing the failure of welded steel components in construction systems,\u0026rdquo; \u003cem\u003eJ. Fail. Anal. Prev.\u003c/em\u003e, vol. 18, no. 2, pp. 304\u0026ndash;314, Apr. 2018.\u003c/li\u003e\n\u003cli\u003e\u0026ldquo;3. bir_kazici_y\u0026uuml;kleyic_makinenin.\u0026rdquo; .\u003c/li\u003e\n\u003cli\u003eJ. Selech \u003cem\u003eet al.\u003c/em\u003e, \u0026ldquo;A working design of a bulldozer blade as additional equipment of a compaction drum roller,\u0026rdquo; \u003cem\u003eMATEC Web Conf.\u003c/em\u003e, vol. 254, p. 04005, 2019.\u003c/li\u003e\n\u003cli\u003eP. Patel and J. M. Prajapati, \u0026ldquo;A review on fea and optimization of backhoe attachment in hydraulic excavator,\u0026rdquo; \u003cem\u003eIACSIT International Journal of Engineering and Technology\u003c/em\u003e, vol. 3, no. 5, pp. 505\u0026ndash;511, 2011.\u003c/li\u003e\n\u003cli\u003eO. G\u0026ouml;lbaşi and N. Demirel, \u0026ldquo;Investigation of stress in an earthmover bucket using finite element analysis: A generic model for draglines,\u0026rdquo; \u003cem\u003eJ. S. Afr. Inst. Min. Metall.\u003c/em\u003e, vol. 115, no. 7, pp. 623\u0026ndash;628, Jul. 2015.\u003c/li\u003e\n\u003cli\u003e\u0026ldquo;5. Finite Element Analysis on Working Mechanism of Hydraulic Excavator.\u0026rdquo; .\u003c/li\u003e\n\u003cli\u003eR. M. Dhawale and S. R. Wagh, \u0026ldquo;Finite element analysis of components of excavator arm- a review,\u0026rdquo; \u003cem\u003eInt J Mech Eng \u0026amp; Rob Res\u003c/em\u003e, vol. 3, no. 2, pp. 1\u0026ndash;7, 2014.\u003c/li\u003e\n\u003cli\u003eD. Mahto and N. E. Mastorakis, \u003cem\u003eVisualization of Strain influence on cutting edge of different Austempered Ductile Iron (ADI) products: FEA in Dozer Blade with ANSYS\u003c/em\u003e. 2016.\u003c/li\u003e\n\u003cli\u003eT. Karag\u0026ouml;z, \u003cem\u003eA Finite Elements Based Approach For Fracture Analysis Of Welded Joints In Construction Machinery\u003c/em\u003e. 2007.\u003c/li\u003e\n\u003cli\u003eS. H. Suryo, R. S. Sastra, Muchammad, and Harto, \u0026ldquo;Optimization of bucket tooth excavator design using topology optimization and finite element method,\u0026rdquo; \u003cem\u003eJ. Phys. Conf. Ser.\u003c/em\u003e, vol. 1858, no. 1, p. 012081, Apr. 2021.\u003c/li\u003e\n\u003cli\u003eB. P. Patel and J. M. Prajapati, \u0026ldquo;An Excavation Force Calculations and Applications: An Analytical Approach,\u0026rdquo; \u003cem\u003eInternational Journal of Engineering Science and Technology\u003c/em\u003e, vol. 3, no. 5, pp. 3831\u0026ndash;3837, 2011.\u003c/li\u003e\n\u003cli\u003eG. Kiper, C. C. Uzer, and M. Karabey, \u0026ldquo;Kineostatic Analysis and Arm Cylinder Design For An Excavator Arm Mechanism,\u0026rdquo; in \u003cem\u003e19. ULUSAL MAKİNA TEORİSİ SEMPOZYUMU\u003c/em\u003e, 2019.\u003c/li\u003e\n\u003cli\u003eM. Yener, \u003cem\u003eDesign Of A Computer Interface For Automatic Finite Element Analysis Of An Excavator Boom\u003c/em\u003e. 2005.\u003c/li\u003e\n\u003cli\u003eL. Pan \u003cem\u003eet al.\u003c/em\u003e, \u0026ldquo;Fatigue analysis of dozer push arms under tilt bulldozing conditions,\u0026rdquo; \u003cem\u003eMachines\u003c/em\u003e, vol. 10, no. 1, p. 38, Jan. 2022.\u003c/li\u003e\n\u003cli\u003eY.-S. Lee, S.-H. Kim, J. Seo, J. Han, and C.-S. Han, \u0026ldquo;Blade control in Cartesian space for leveling work by bulldozer,\u0026rdquo; \u003cem\u003eAutom. Constr.\u003c/em\u003e, vol. 118, no. 103264, p. 103264, Oct. 2020.\u003c/li\u003e\n\u003cli\u003eM. Doudkin, A. Kim, B. Aukenova, R. Radenkov, A. Saveliev, and N. Andryukhov, \u0026ldquo;Theoretical investigations of the process of interaction with the environment of a bulldozer bladow with variable geometry,\u0026rdquo; \u003cem\u003eIstraz. Proj. Za Privredu\u003c/em\u003e, pp. 1\u0026ndash;10, Jul. 2022.\u003c/li\u003e\n\u003cli\u003eD. T, P. Y, and K. Y, \u0026ldquo;Study of forces acting on excavator bucket while digging,\u0026rdquo; \u003cem\u003eJ. Appl. Mech. Eng.\u003c/em\u003e, vol. 06, no. 05, 2017.\u003c/li\u003e\n\u003cli\u003eY. Z. Demi̇r and Y. Usta, \u0026ldquo;Kazıcı Y\u0026uuml;kleyici Makineler i\u0026ccedil;in Kazıcı Kep\u0026ccedil;e ile \u0026Ccedil;alışan Hidrolik Bir \u0026Ccedil;ene Tasarımı ve Denenmesi,\u0026rdquo; \u003cem\u003eMuş Alparslan \u0026Uuml;niv. Fen Bilim. Derg.\u003c/em\u003e, vol. 7, no. 1, pp. 621\u0026ndash;634, Jun. 2019.\u003c/li\u003e\n\u003cli\u003eM. Z. Tekeste, T. R. Way, Z. Syed, and R. L. Schafer, \u0026ldquo;Modeling soil-bulldozer blade interaction using the discrete element method (DEM),\u0026rdquo; \u003cem\u003eJ. Terramech.\u003c/em\u003e, vol. 88, pp. 41\u0026ndash;52, Apr. 2020.\u003c/li\u003e\n\u003cli\u003eM. M. Cucos, I. M. Pista, and M. I. Ripanu, \u0026ldquo;Product engineering design enhancing by parameterizing the 3D solid model,\u0026rdquo; \u003cem\u003eMATEC Web Conf.\u003c/em\u003e, vol. 178, p. 05011, 2018.\u003c/li\u003e\n\u003cli\u003eM. S. Islam, F. Khan, and M. Hossain, \u0026ldquo;Vibration reduction of an excavator bucket using attachment technique,\u0026rdquo; \u003cem\u003eInt. Rev. Mech. Eng. (IREME)\u003c/em\u003e, Jul. 2020.\u003c/li\u003e\n\u003cli\u003eX. Zeng, J. Huo, H. Wang, Z. Wang, and M. Elchalakani, \u0026ldquo;Dynamic tensile behavior of steel HRB500E reinforcing bar at low, medium, and high strain rates,\u0026rdquo; \u003cem\u003eMaterials (Basel)\u003c/em\u003e, vol. 13, no. 1, p. 185, Jan. 2020.\u003c/li\u003e\n\u003cli\u003eF. Uzun and A. M. Korsunsky, \u0026ldquo;Voxel‐based full‐field eigenstrain reconstruction of residual stresses,\u0026rdquo; \u003cem\u003eAdv. Eng. Mater.\u003c/em\u003e, Apr. 2023.\u003c/li\u003e\n\u003cli\u003eK. Bao, Q. Zhang, Y. Liu, and J. Dai, \u0026ldquo;Fatigue life of the welding seam of a tracked vehicle body structure evaluated using the structural stress method,\u0026rdquo; \u003cem\u003eEng. Fail. Anal.\u003c/em\u003e, vol. 120, no. 105102, p. 105102, Feb. 2021.\u003c/li\u003e\n\u003cli\u003eKirkhope KJ, Bell R, Caron L, Basu RI, Ma KT,\u0026quot; Weld detail fatigue life improvement techniques. Part 1: review\u0026quot;Marine structures, vol.12, no.6, p. 447-474,1999.\u003c/li\u003e\n\u003cli\u003eW. Rudorffer, M. W\u0026auml;chter, A. Esderts, F. Dittmann, and I. Varfolomeev, \u0026ldquo;Fatigue assessment of weld seams considering elastic\u0026ndash;plastic material behavior using the local strain approach,\u0026rdquo; \u003cem\u003eWeld. World\u003c/em\u003e, Jan. 2022.\u003c/li\u003e\n\u003cli\u003eS. B. Wu and X. B. Liu, \u0026ldquo;Improvements for a hydraulic excavator\u0026rsquo;s boom,\u0026rdquo; \u003cem\u003eAppl. Mech. Mater.\u003c/em\u003e, vol. 490\u0026ndash;491, pp. 510\u0026ndash;513, Jan. 2014.\u003c/li\u003e\n\u003cli\u003eC. Yu, Y. Bao, and Q. Li, \u0026ldquo;Finite element analysis of excavator mechanical behavior and boom structure optimization,\u0026rdquo; \u003cem\u003eMeasurement (Lond.)\u003c/em\u003e, vol. 173, no. 108637, p. 108637, Mar. 2021.\u003c/li\u003e\n\u003cli\u003eZ. Feng, N. Ma, S. Tsutsumi, and F. Lu, \u0026ldquo;Investigation of the residual stress in a multi-pass T-welded joint using low transformation temperature welding wire,\u0026rdquo; \u003cem\u003eMaterials (Basel)\u003c/em\u003e, vol. 14, no. 2, p. 325, Jan. 2021.\u003c/li\u003e\n\u003c/ol\u003e"}],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":true,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":false,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":true,"isPdf":false,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Finite Element Analysis (FEA), dozer blade, stress distribution, welding stresses, design modifications, fatigue resistance, structural integrity, manufacturing optimization","lastPublishedDoi":"10.21203/rs.3.rs-5915133/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-5915133/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThe Finite Element Analysis (FEA) conducted on the HMK 230LC dozer blade provided valuable insights into the structural behavior and stress distribution under various operational conditions. The analysis identified critical stress concentrations, particularly at welded joints and connection points, with maximum principal stresses reaching 120 MPa. These areas, influenced by geometric changes and loading conditions, were essential for evaluating the structural integrity and durability of the dozer blade. Design modifications, such as increasing the mirror sheet thickness by 50%, significantly reduced bending effects and improved load distribution, resulting in a 14% reduction in welding stresses at critical joints. This adjustment helped maintain stress levels within safe operational limits, improving overall structural reliability. Re-analysis post-modification confirmed a significant reduction in localized stress concentrations and bending effects, enhancing resistance to mechanical fatigue and increasing structural durability. The study also emphasized the importance of high-quality welding, especially at junctions between the main support and blade arms, to prevent stress-induced failures. Recommendations for further improvements include post-weld heat treatments, material reinforcements, and advanced welding techniques. The study underscores the need for real-world testing, such as strain gauge experiments, to validate simulation results and further optimize future designs for better performance and longevity.\u003c/p\u003e","manuscriptTitle":"Optimization of an Excavator Dozer Blade Using the Finite Element Method: Evaluating Upper Group Alignment at Zero Degrees to the Lower Group","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-03-28 12:51:47","doi":"10.21203/rs.3.rs-5915133/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"reviewerAgreed","content":"","date":"2025-09-19T00:50:00+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-03-19T17:07:24+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-01-31T02:08:25+00:00","index":"","fulltext":""},{"type":"submitted","content":"The International Journal of Advanced Manufacturing Technology","date":"2025-01-29T04:02:19+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"00d4e6bb-dc5b-47d1-8f7d-2bc65ff3fbc5","owner":[],"postedDate":"March 28th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"published-in-journal","subjectAreas":[],"tags":[],"updatedAt":"2026-01-12T16:01:07+00:00","versionOfRecord":{"articleIdentity":"rs-5915133","link":"https://doi.org/10.1007/s00170-025-17256-2","journal":{"identity":"the-international-journal-of-advanced-manufacturing-technology","isVorOnly":false,"title":"The International Journal of Advanced Manufacturing Technology"},"publishedOn":"2026-01-05 15:57:26","publishedOnDateReadable":"January 5th, 2026"},"versionCreatedAt":"2025-03-28 12:51:47","video":"","vorDoi":"10.1007/s00170-025-17256-2","vorDoiUrl":"https://doi.org/10.1007/s00170-025-17256-2","workflowStages":[]},"version":"v1","identity":"rs-5915133","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-5915133","identity":"rs-5915133","version":["v1"]},"buildId":"XKTyCvWXoU3ODBz1xrDgd","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}