Design optimization and development of SMC composite tray

In the engineering application, trays are easy to break down to result in anchorage failure in the composite anchoring systems. Therefore, the research carried out the force analysis with mechanics of materials to observe the main stress concentration and deformation of the tray. From the findings of the force analysis, the structure and key parameters of the tray were optimized with reference of the existing tray design. Besides, the study turns to the finite element software to simulate and analyze the tray. The results manifest that tray failure during the support mainly results from the expansion and deformation of the taper hole squeezed by the nut, which causes the tray taper hole to rupture and crackle extend, thus leading to its crack. What’s more, the tray breaks for the compression of the tray edge by the surrounding rock. The maximum deformation at the large end of the optimized tray tapered hole was reduced from 33.8 mm to 4.7 mm, approximately 86% with the shear stress reduced from 781.67 Mpa to 258.83 Mpa, about 66.8%. Using Sheet Molding Compound (SMC) to mould trays with new structure and conducting the test of tray bearing capacity, it can be found that its bearing capacity is up to 250 KN. After the taper hole of the tray is locally strengthened, its bearing capacity is increased to 304 KN.