FLOW UNIVERSITY THESIS

CRANK HOOK

TRẦN THANH PHONG

Students: Nguyễn Hoàng Đạt 20143193 Mai Hoàng Dũng 18144012 Nguyễn Tường Duy 21143253

CAE

A crank hook in an industrial context typically refers to a specialized hook or lifting device that is attached to a mechanical crank mechanism. Crank hooks are commonly used in various industrial applications where heavy lifting and precise positioning of loads are required.

WHAT IS CRANK HOOK ??

INDEX

04.CRANE HOOK MODELLINGAND MATERIAL SELECTION

01. Object

06. Conlution

02. Research Objectives

05. STRUCTURAL AND FATIGUE ANALYSIS USING ANSYS WORKBENCH AND ANSYS NCODE DESIGNLIFE

03. Research Menthod

01. OBJECT

CRANE HOOK

• Reduce structure failure of crane hook, induced stress in crane hook is analyzed properly.

• Fatigue, damage is the initiation of a crack due to fluctuating loading.

• It is highly responsible and important component being used for industrial works.

The structure strength is an important signal to response the load bearing capability of the elevating equipment.Crane hook is a curved bar and is used for lifting loads in cranes.

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02. Research Objectives

In the present work, study of different candidates of crane hook of trapezoidal cross section based on design parameters are carried out and weight optimization iscarried out by varying the design parameters.

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03. RESEARCH METHOD

GeneralsOPTIMIZATION AND FATIGUE ANALYSISOF A CRANE HOOK USINGFINITE ELEMENT METHOD

1.Mean stress effects

• Goodman and Gerber theories are based on the assumption that the alternating stress range and tensile mean DOI : 10.14810/ijmech.2015.4403 stress are either linearly (Goodman) or parabolically(Gerber) related.

• The material selected has elongation greater than 5% and is ductile in nature .
• Therefore the theory considered is Gerber which is best suited for ductile materials

• Alternating peak stress range is the primary influence on fatigue life.
• Mean stress that occurs during the loading is a secondary effect.

• Tensile mean stresses reduce fatigue life and compressive mean stresses increase fatigue life which is commonly ignored.

03. RESEARCH METHOD

GeneralsOPTIMIZATION AND FATIGUE ANALYSISOF A CRANE HOOK USINGFINITE ELEMENT METHOD

2.Stress Combination Method

• The analysis cell creates a stress tensor history
• For fatigue calculation, this stress tensor should be reduced to a scalar value, so that it can be cycle counted and the resulting cycles can be compared to an S-N curve or curves.

• Where,
• σSVM = signed von-mises stress.
• σAMP = absolute maximum principal stress.
• σ1, σ2, σ3= principal stresses.

03. RESEARCH METHOD

GeneralsOPTIMIZATION AND FATIGUE ANALYSISOF A CRANE HOOK USINGFINITE ELEMENT METHOD

2.Surface Effects

• Where,Ktreatment = surface treatment factor
• Kuser = user surface factor
• Kroughness = surface roughness factor

• Where,RM is Ultimate tensile strength (U.T.S) in MPa.

• ar&Rm,N,min are constants and function of type of material and its Ultimate tensile strength (U.T.S). For AISI 4340 150, ar=0.22&Rm,N,min= 400 [7].Therefore, value of Kr obtained is 0.871.

04.CRANE HOOK MODELLINGAND MATERIAL SELECTION

Hook Modelling Using Solid works

• Curved bars are frequently subjected to axial or bending loads or a combination of both axial and bending loads.
• Computer Aided Design (CAD) is the very first stage of any project and the shapes drafted in CAD software will be considered in Finite Element Analysis (FEA) software for analysis.The design of crane hook is made in Solidworks.
• The dimensions of cross-section of the
• actual design of crane hook are given in the 2D drawing shown in fig. 1. The CAD model of
• crane hook is shown in fig. 2.

Dimensions (in mm) of trapezoida lcross-section.

H1

Crane hook CAD model.

H2

04.CRANE HOOK MODELLINGAND MATERIAL SELECTION

Material Assigned

• In the present work, the material selected is AISI 4340 150. Along with the mechanical properties of AISI 4340 150, some fatigue parameters are also listed in the table 1. For this material,

• Numerical fatigue cutoff life is 1E8 i.e., damage due to fatigue will be assumed zero beyond this numerical fatigue cutoff life [7].

05.STRUCTURAL AND FATIGUE ANALYSIS USING ANSYS WORKBENCH AND ANSYS NCODE DESIGNLIFE

1. Static Structure Analysis

The first step in simulation process for structure analysis is to assign the material, apply boundary conditions and then generate mesh. A load of 30 ton is applied and the degree of freedom (DOF) of top of the crane hook is zero i.e., it is fully constrained

Boundary Conditions.

05.STRUCTURAL AND FATIGUE ANALYSIS USING ANSYS WORKBENCH AND ANSYS NCODE DESIGNLIFE

1. Static Structure Analysis

Contour plots of equivalent (von-mises) stress and total deformation for actual design are shown in the fig(a) and (b) respectively

Equivalent (von mises) stress and Total deformation of actual crane hook..

05.STRUCTURAL AND FATIGUE ANALYSIS USING ANSYS WORKBENCH AND ANSYS NCODE DESIGNLIFE

1. Static Structure Analysis

• The upper bound and lower bound of length of ‘D’is 125 mm and 100 mm respectively whereas the value of‘d’ varies from 40 mm to 55 mm.

• Table shows the mass, equivalent(von-mises) stress and total deformation results of the different candidates obtained.

05.STRUCTURAL AND FATIGUE ANALYSIS USING ANSYS WORKBENCH AND ANSYS NCODE DESIGNLIFE

1. Static Structure Analysis

• The main objective of this study is weight optimization. Therefore, the objective importance of mass is considered higher.
• Based on this, best three candidates are selected out of the 24 candidates shown in table

05.STRUCTURAL AND FATIGUE ANALYSIS USING ANSYS WORKBENCH AND ANSYS NCODE DESIGNLIFE

1. Static Structure Analysis

Equivalent (von-mises) stress and Total deformation of crane hook having D=100mm & d=40mm.

05.STRUCTURAL AND FATIGUE ANALYSIS USING ANSYS WORKBENCH AND ANSYS NCODE DESIGNLIFE

1. Static Structure Analysis

Equivalent (von-mises) stress and Total deformation of crane hook having D=100mm & d=45mm

05.STRUCTURAL AND FATIGUE ANALYSIS USING ANSYS WORKBENCH AND ANSYS NCODE DESIGNLIFE

1. Static Structure Analysis

Equivalent (von-mises) stress and Total deformation of crane hook having D=105mm & d=40mm.

05.STRUCTURAL AND FATIGUE ANALYSIS USING ANSYS WORKBENCH AND ANSYS NCODE DESIGNLIFE

2.Fatigue Analysis

• Fatigue analysis is carried out for the actual model and the best 3 candidates obtained and two fatigue contours are plotted.
• The two contour plots are fatigue life and fatigue damage. In the present study, the type of load mapping used for fatigue analysis is constant amplitude load mapping.
• Constant amplitude load mapping assumes FE stress/strain results to cycle between minimum and maximum values.
• The nCode DesignLife SN constant amplitude load mapping engine is drag onto the solution cell of themechanical system to generate file.rst file which reads node & element information and FE stress/strain results as shown in fig.

Project Schematic.

05.STRUCTURAL AND FATIGUE ANALYSIS USING ANSYS WORKBENCH AND ANSYS NCODE DESIGNLIFE

2.Fatigue Analysis

Result

Fatigue life and damage contour plots of actual crane hook.

05.STRUCTURAL AND FATIGUE ANALYSIS USING ANSYS WORKBENCH AND ANSYS NCODE DESIGNLIFE

2.Fatigue Analysis

Result

Fatigue life and damage contour plots of crane hook having D=100 mm, d=40 mm.

05.STRUCTURAL AND FATIGUE ANALYSIS USING ANSYS WORKBENCH AND ANSYS NCODE DESIGNLIFE

2.Fatigue Analysis

Result

Fatigue life and damage contour plots of crane hook having D=100 mm, d=45 mm.

05.STRUCTURAL AND FATIGUE ANALYSIS USING ANSYS WORKBENCH AND ANSYS NCODE DESIGNLIFE

2.Fatigue Analysis

Result

Fatigue life and damage contour plots of crane hook having D=105 mm, d=40 mm.

05.STRUCTURAL AND FATIGUE ANALYSIS USING ANSYS WORKBENCH AND ANSYS NCODE DESIGNLIFE

2.Fatigue Analysis

Result

• The comparison of the fatigue life of each candidate is shown in table.
• The comparison of fatigue damage of each crane hook is shown in table.
• On the basis of fatigue analysis results obtained, Candidate No.3 can withstand the maximum number of fatigue cycles before failure i.e., the minimum fatigue life obtained is 8.805E7 repeats which is better than the other two candidates.

Comparison of fatigue results of the actual model and the best three candidates.

06.CONCLUSION

The results of static structure analysis are obtained from the FEA software Ansys for different cross sections. In this study, we finally conclude that out of 24 candidates obtained, 3 best candidates are considered on the basis of minimum weight criteria. As a result, weight of crane hook is reduced for the same load.

In the present work, the geometry of the crane hook is modelled and finite element analysis (FEA) is applied on the model.

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06.CONCLUSION

• As a result, 1 candidate is selected on the basis of fatigue analysis having maximum fatigue life and it is compared with the actual crane hook model as shown in table

• The weight of the final candidate is reduced by 15.861 Kg compared to actual hook model.
• The weight optimization of the crane hook is achieved by taking parallel sides of the cross section of crane hook as the design variables.
• The minimum fatigue life of the final candidate obtained is decreased and stress value is increased by 14.04 MPa which is within limits and practically acceptable.
• The weight of the hook is reduced by 22.03% which can be accepted as a optimize result.

Comparison of the actual crane hook model and the best candidate obtained after weight optimization.

06.Methodology

Procedures and variables

Instruments

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