Department of Mechanical and Industrial Engineering

ME 4508: Mechanical Engineering Computation & Design (Spring 2016)

Finite Element Analysis on the Mighty Handle Bag Carrier
Submitted by
Samantha Bell
Abstract
The Mighty Handle is a device designed to make carrying extra grocery bags more
comfortable and convenient. The packaging of the Mighty Handle claims that it can carry up
to 50 pounds per handle. Various loading cases for the Mighty Handle geometry were run
through a finite element analysis in ANSYS APDL to attempt to validate these claims. It was
assumed the Mighty Handle is made of ABS/PC with a Youngs Modulus of 2.4 GPa and a
Poissons Ratio of 0.36 with a tensile strength range of 44-124 MPa. Loading cases 1 and 3
have a maximum Von-Mises stress that fell below 44 MPa, meaning they can successfully
sustain 50 pound loading for any ABS/PC plastic. However, case 2 has a maximum Von-Mises
stress of 48.3 MPa, just above 44 MPa, so if a low to moderate strength ABS/PC is used case
2 is successful. Lastly, case 4 has a maximum Von-Mises stress of 67.3 MPa which falls in the
middle of the range. Therefore, for all loading cases to meet Mighty Handles claims of being
able to sustain 50 pounds per handle, it needs to be made of a high strength ABS/PC. If the
Mighty Handle is made of a low to moderate strength ABS/PC then loading case 4 will fail.

Date Submitted:

20 April 2016

Course Instructor:

Ashkan Vaziri

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Introduction/Purpose
Mighty Handle is a consumer product designed to help carry extra grocery bags or other
items that are hard to carry, such as paint cans, as shown in Figure 1 [1].

Figure 1- Mighty Handle

Carrying grocery bags is the cause of much discomfort for many people, especially if they are
carrying plastic bags. Many devices have been created to attempt to solve this problem and
relieve the pain caused by carrying bags. Everyone needs to go grocery shopping, and
everyone at some point has carried a lot of bags or one very heavy bag that has been
extremely painful. Devices such as Mighty Handle are more useful for people who walk to
the grocery store, but are also very useful for people who have to park far from their home
(such as people in the city) or live a few floors off the ground and do not like to climb their
stairs multiple times to bring their groceries up. Mighty Handles motto is: More Bags. One
Trip. No Spills. [1] The Mighty Handle helps accomplish this motto by allowing you to carry
many bags in one hand without the handles of the bag digging into your hand and causing
discomfort. Due to this goal, Mighty Handle needs to be capable of sustaining a large load.
However, due to the nature of being a consumer product, it also needs to be able to withstand
this load in as many ways as users can think to load it. This report investigates Mighty
Handles claims to be able to carry up to 50 pounds per handle. Multiple loading scenarios,
equivalent to 50 pounds, will be tested using finite element analysis using ANSYS APDL to
determine if there is any reasonable scenario in which Mighty Handle cannot sustain 50
pounds of force. Reasonable scenarios will be considered any loading case where the force
is applied on the inner radii of bottom half of the device, as shown in Figure 2, due to the
effects of gravity pulling the bags to the lowest point.

Inner Radii

Figure 2 - Definition of Reasonable Scenarios

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Methods
Before running the finite element analysis, a 3D model must be generated to run the finite
element analysis on. Before making the 3D model in SolidWorks, a few assumptions were
made to simplify the model. First, the ribs along the front and back face of the Mighty Handle
were ignored and a simple extrude with flat faces was assumed. Second, the green rubber
handle on the top of the Mighty Handle has no effect on the structural capabilities of the
device, so it was ignored for modeling purposes. Lastly, the widths of members were
assumed to be constant in the top half and bottom half of the device, although there were
slightly variations in width, it was roughly 0.38 for the top half and 0.40 for the bottom half.
Measurements were taken as accurately as possible with a pair of six-inch Neiko digital
calipers. The 3D model was made with a simple sketch, as shown in Figure 3, based on the
measurements, and a 0.25 extrusion.

Figure 3 - Sketch Used to Model the Mighty Handle

The final 3D model is as shown in Figure 4.

Figure 4 - Final 3D Model of Mighty Handle

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Once the 3D model was complete in SolidWorks, it was imported into ANSYS APDL as a
parasolid (.x_t). Once imported into ANSYS APDL, the model needs to be set up for finite
element analysis. When a 3D model is imported into ANSYS APDL, all dimensions are
converted to meters, so the SI system must be used for all inputs into ANSYS. The element
type is set as Solid, Brick 8 Node 185 with no real constants. Next material properties need
to be entered. Going back to the physical Mighty Handle, it is marked as plastic #7 for
recyclability purposes. Plastic #7 is the other category for recyclability. Category 7 has
many polycarbonate compounds [2]. It is then assumed that the Mighty Handle is made of
an ABS/PC (acrylonitrile butadiene styrene / polycarbonate) compound. ABS/PC is a very
common low cost yet high strength material often used for injection molding processes
(the manufacturing method of the Mighty Handle). ANSYS APDL requires the Youngs
Modulus and Poissons Ratio for the material, ABS/PC. Looking up the mechanical
properties of ABS/PC from injection molding vendor ProtoLabs gives a flexural modulus of
300,000 390,000 psi (2068 2689 MPa) and a tensile strength of 6,400 18,000 psi (44
124 MPa) [3]. For plastics, the flexural modulus can be used as a substitute for elastic
modulus for finite element analysis [4]. The elastic modulus for ABS/PC is entered into
ANSYS APDL as the average of the range given by ProtoLabs, 2378.5 MPa. The Poissons
ratio for ABS/PC is unknown, but the Poissons ratio for ABS is 0.35, and for PC is 0.37, so
the Poissons ratio for ABS/PC when input in ANSYS APDL is estimated at 0.36 [5]. Once the
material model and element type are input, the model can be meshed. Using the Mesh Tool,
with Smart Size selected and set to Fine, as well as Tet as the mesh shape, Pick All is used to
mesh the entire volume of the Mighty Handle in ANSYS APDL. Now that the object has been
meshed, the loads need to be applied. First, the structural loads are applied to constrain the
motion of the part. To constrain the Mighty Handle, similar to how it is meant to be used, all
degrees of freedom for the area shown in Figure 5 were set to zero. This simulates the
Mighty Handle being held by the top member.

Figure 5 - Mighty Handle with Structural Constraints

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All that is left to set up the finite element analysis is the various reasonable scenarios for
loading conditions equivalent to 50 pounds. The four reasonable scenarios to be tested are
shown in Figure 6, where the total force value is shown.

25 lbs

25 lbs

50 lbs

(a) Case 1

(b) Case 2

(c) Case 3

(d) Case 4

Figure 6 - Four Reasonable Scenarios for Loading of the Mighty Handle

To model these four scenarios in ANSYS APDL, constant value pressure loads will be used
on areas, with the loading value set equivalent to a 25-pound or 50-pound point force
based on the scenario. To determine the value for the loading force, the areas of the faces
to be loaded need to be known. Using the SolidWorks measure tool, the area of the two
faces were calculated, as shown in Figure 7.

(a)

(b)

Figure 7- Determining Areas of Loaded Faces in Solidworks

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The face measured in Figure 7 (a) will be referred to as face 1, and the face measured in
Figure 7 (b) will be referred to as face 2. SolidWorks found the area of face 1 to be
0.154964 in2, and the area of face 2 to be 0.499595 in2. For ease of calculations, these areas
will be rounded to 0.155 in2 and 0.5 in2.
With the areas now known, the pressure loads can be determined. Since ANSYS APDL
inputs 3D models and converts all values to the SI system, the pressure load will need to be
inputted in Pa (N/m2). Using the total force required for each loading scenario, the
pressure load values were calculated using Equation 1.
() =

()
(2 )

(1)

The values for the pressure load were then converted to Pa from psi. Table 1 shows the
pressure load values required for ANSYS APDL modeling.
Table 1- Pressure Load Values Required for ANSYS Modeling

Face 1 (0.155 in2)

(psi)
(MPa)
161.29
1.11
322.58
2.22

Equivalent Force (lbs)

25
50

Face 2 (0.5 in2)

(psi)
(MPa)
50
0.345
100
0.689

The four cases were then modeled in ANSYS APDL with the appropriate pressure loads as
shown in figures 8 through 11.

(a)

(b)
Figure 8- Case 1 Modeled in ANSYS APDL

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(a)

(b)
Figure 9- Case 2 Modeled in ANSYS APDL

(a)

(b)
Figure 10 - Case 3 Modeled in ANSYS APDL

(a)

(b)
Figure 11- Case 4 Modeled in ANSYS APDL

After modeling the loading and constraints, the four different scenarios were solved.

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Results
Case 1: Two 25-lb forces, one on each instance of face 1

Max Stress

(a)

(b)

Figure 12 - Displacement & Von-Mises Stress Plots for Case 1

Figure 12 (a) shows the displacement plot for case 1, showing the maximum displacement is
0.755 mm.
Figure 12 (b) shows the plot of Von-Mises stress for case 1, showing the maximum Von-Mises
stress is 19.3 MPa at the location highlighted by the red circle.
Case 2: One 50-lb force on one instance of face 1

Max Stress

(a)

(b)

Figure 13- Displacement & Von-Mises Stress Plots for Case 2

Figure 13 (a) shows the displacement plot for case 2, showing the maximum displacement is
6.436 mm.
Figure 13 (b) shows the plot of Von-Mises stress for case 2, showing the maximum Von-Mises
stress is 48.3 MPa at the location highlighted by the red circle.

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Case 3: Two 25-lb forces, one on each instance of face 2

Max Stress

(a)

(b)

Figure 14 - Displacement & Von-Mises Stress Plots for Case 3

Figure 14 (a) shows the displacement plot for case 3, showing the maximum displacement is
3.802 mm.
Figure 14 (b) shows the plot of Von-Mises stress for case 3, showing the maximum Von-Mises
stress is 33.8 MPa at the locations highlighted by the red circles.
Case 4: One 50-lb force on one instance of face 2

Max Stress

(a)

(b)

Figure 15 - Displacement & Von-Mises Stress Plots for Case 4

Figure 15 (a) shows the displacement plot for case 4, showing the maximum displacement is
14.704 mm.

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Figure 15 (b) shows the plot of Von-Mises stress for case 4, showing the maximum Von-Mises
stress is 67.3 MPa at the location highlighted by the red circle.
Discussion/Conclusions
To determine if the Mighty Handle is capable of withstanding 50 pound forces, the maximum
Von-Mises stress is compared the tensile strength at yield for ABS/PC. ProtoLabs lists the
tensile strength for ABS/PC as 6,400 18,000 psi (44 124 MPa) [3], and MatWeb lists the
tensile strength at yield at 65.0 MPa for Cycoloy CX7240 PC+ABS [6]. Given the nature of
ABS/PC as a compound of two plastics, there are various combinations with various ratios
of PC to ABS. It has already been assumed that the Mighty Handle is made of some ABS/PC
resin, but the exact ratio of ABS to PC is impossible to make a close estimate without
significant mechanical testing of the device. Due to this, the maximum Von-Mises stresses for
each case were compared to the range supplied by ProtoLabs to determine if it seems likely,
given the analysis of the Mighty Handle, that they are made of an ABS/PC material and if their
claims for carrying up to 50 pounds are reasonable.
Table 2 - Maximum Von-Mises Stresses for Each Loading Case
Case #

Maximum Von-Mises Stress (MPa)

19.3

48.3

33.8

67.3

Table 2 shows the maximum Von-Mises stresses for each loading case. Case 1 has the lowest
maximum Von-Mises stress at 19.3 MPa, followed by case 2 at 33.8 MPa, then with case 2 at
48.3 MPa, with case 4 having the highest maximum Von-Mises stress at 67.3 MPa. Comparing
to ProtoLabs range of tensile strength for ABS/PC of 44-124 MPa, it is seen that for cases 1
and 3, the maximum Von-Mises stresses fall below 44 MPa, which was the smallest tensile
strength listed, and cases 2 and 4 fall somewhere within the range listed in the lower half.
Therefore it can be concluded that if the Mighty Handle is made of ABS/PC that loading cases
1 and 3 can always withstand the 50 pound loading, regardless of ABS to PC ratio. However,
loading cases 2 and 4 are more reliant on the specific ABS to PC ratio. Case 2, with a maximum
Von-Mises stress of 48.3 MPa is very close to the low end of ProtoLabs range of 44 MPa, so
it does not require an extremely strong ABS/PC mixture, but case 4 with a maximum VonMises stress of 67.3 falls in the middle of the range. Therefore, if one is to assume that all of
the loading cases can support the 50 pounds in real life the specific ABS/PC used must be a
high strength one when you add in a safety factor. However, if they Mighty Handle is made
of not a high strength ABS/PC and rather a low to moderate strength one, all loading cases
but case 4 would be able to successfully support a 50 pound load.

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References
[1]"Mighty Handle - Carry Plastic Shopping Bags With Ease", Mightyhandle.com, 2016.
[Online]. Available: http://www.mightyhandle.com. [Accessed: 18- Apr- 2016].
[2]"Eartheasy Blog Plastics by the Numbers", Learn.eartheasy.com, 2012. [Online].
Available: http://learn.eartheasy.com/2012/05/plastics-by-the-numbers/. [Accessed: 18Apr- 2016].
[3]"Injection Molding Materials Guide", Protolabs.com. [Online]. Available:
https://www.protolabs.com/resources/materials/molding-materials. [Accessed: 18- Apr2016].
[4]K. Pedersen, "Frequently Asked Questions on Material Properties for Simulation
Answered", CAPUniversity, 2013. [Online]. Available:
http://blog.capinc.com/2013/09/frequently-asked-questions-on-material-properties-forsimulation-answered/. [Accessed: 18- Apr- 2016].

[5]Mechanical Properties of Plastic Materials, 1st ed. Professional Plastics.

[6]"SABIC Innovative Plastics Cycoloy CX7240 PC+ABS", Matweb.com. [Online]. Available:
http://www.matweb.com/search/datasheet.aspx?matguid=cec804608728465c90fdaf606
3376596. [Accessed: 19- Apr- 2016].

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