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<p>Forklifts are crucial equipment in various industries for efficiently handling and transporting palletized goods. A critical forklift component is the fork, which directly interacts with the load and experiences significant stresses during operation. Ensuring the fork's structural integrity and optimizing its design are vital for safety, performance, and durability. In this research, a hydraulic-operated manual forklift is taken for investigation and studied for how the design optimization of the fork affects the life cycle of the forklift. The design optimization of the forklift’s fork, performed using the ANSYS (v2023 R1) Direct Optimization module, resulted in a redesigned fork with a maximum equivalent stress of 234.16&#xa0;MPa. The optimized forklift assembly, after static structural analysis, showed an improvement of 48% compared to the existing one indicating enhanced performance. Further modal analysis is also carried out to find out the various modes &amp; mode shapes and also to compare the natural frequency of the existing forklift and the one with a modified fork to ensure a performance improvement. Finally, the design optimization of the forklift fork, using the direct optimization module of ANSYS, resulted in a significant reduction of maximum equivalent stress and an extension of the forklift's lifecycle, demonstrating the effectiveness of this approach for improving forklift performance and durability.</p>

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Redefining forklift longevity: a study on fork design optimization and lifecycle enhancement

  • 期刊论文

  • 发表日期：

    2025年1月3日

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  • M. Kumaran,
  • N. Muthuram,
  • S. Hari Chealvan

摘要

Forklifts are crucial equipment in various industries for efficiently handling and transporting palletized goods. A critical forklift component is the fork, which directly interacts with the load and experiences significant stresses during operation. Ensuring the fork's structural integrity and optimizing its design are vital for safety, performance, and durability. In this research, a hydraulic-operated manual forklift is taken for investigation and studied for how the design optimization of the fork affects the life cycle of the forklift. The design optimization of the forklift’s fork, performed using the ANSYS (v2023 R1) Direct Optimization module, resulted in a redesigned fork with a maximum equivalent stress of 234.16 MPa. The optimized forklift assembly, after static structural analysis, showed an improvement of 48% compared to the existing one indicating enhanced performance. Further modal analysis is also carried out to find out the various modes & mode shapes and also to compare the natural frequency of the existing forklift and the one with a modified fork to ensure a performance improvement. Finally, the design optimization of the forklift fork, using the direct optimization module of ANSYS, resulted in a significant reduction of maximum equivalent stress and an extension of the forklift's lifecycle, demonstrating the effectiveness of this approach for improving forklift performance and durability.