Development of a Specialized Fixture for Tensile Testing of Lifting Eyes Used in Dock Leveler Handling

Abstract

This study presents a specialized fixture designed for tensile testing machines to evaluate the mechanical behavior of lifting eyes used in dock leveler handling. The device overcomes the limitations of conventional tensile setups, which cannot reproduce the complex loading conditions generated during forklift operations. It consists of upper and lower subassemblies that enable realistic load transfer and accurate boundary condition simulation. The design process included geometric optimization and structural validation to ensure rigidity, durability, and minimal influence on specimen behavior, supporting loads up to 40 kN. Proper alignment and repeatable positioning were prioritized to improve testing consistency, while the fixture was engineered to reduce parasitic stresses and ensure uniform load distribution. Experimental results confirm that the fixture allows the acquisition of experimentally relevant structural response data under realistic loading conditions and enables more representative loading conditions compared to conventional direct gripping configurations. Overall, the solution enhances safety evaluation and supports refined design of lifting components, offering a methodology adaptable to other mechanically loaded systems.