Design, Analysis and Optimization of Crane Hook

Transcription

1 Design, Analysis and Optimization of Crane Hook 1 Hardik P. Kankotiya, 2 Prof. Nikunj Modh 1 ME Student, 2 Assistant Professor 12 Mechanical Engineering Department 12 VENUS International College of Technology, Bhoyan Rathod. Abstract Crane hook are highly liable components and are always subjected to failure due to accumulation of large amount of stresses which can eventually lead to its failure to study the stress pattern in its loaded condition. In this thesis an overall design of the hoisting mechanism of an EOT crane has been carried out. The dimensions of the main components have been determined for a load capacity of 10 ton crane having 8 rope falls. Various dimensions for cross sections of various shapes for crane hook have been found. After the system was designed, the stress and deflection are calculated at critical points using ANSYS and optimized. Which cross section would be better keeping some parameters constant for all the case. Various dimensions and load per wire for wire ropes has been found. Using various formulae found the dimensions for pulley, Rope-drum. Also calculated the Power and ratings for the motor, brakes used in the hoist mechanism. A solid model of crane hook is prepared as per standard dimension of 10 tone hook with the help of Solid Works parametric software having material mild steel and then it is exported to ANSYS software and load is applied. The location of maximum stress produced within the member is located and identified using FEM. Modal analysis with respect to boundary condition for propose weigh and stress effect on crane hook and find total deformation with respected frequency according to geometry. Index Terms Crane Hook, EOT, Rope-drum, ANSYS, FEM. I. INTRODUCTION A crane is a type of machine, generally equipped with a hoist, wire ropes or chains, and sheaves, that can be used both to lift and lower materials and to move them horizontally. It is mainly used for lifting heavy things and transporting them to other places. It uses one or more simple machines to create mechanical advantage and thus move loads beyond the normal capability of a man. Cranes are commonly employed in the transport industry for the loading and unloading of freight, in the construction industry for the movement of materials and in the manufacturing industry for the assembling of heavy equipment. The first construction cranes were invented by the Ancient Greeks and were powered by men or beasts of burden, such as donkeys. These cranes were used for the construction of tall buildings. Larger cranes were later developed, employing the use of human tread wheels, permitting the lifting of heavier weights. In the High Middle Ages, harbour cranes were introduced to load and unload ships and assist with their construction some were built into stone towers for extra strength and stability. The earliest cranes were constructed from wood, but cast iron and steel took over with the coming of the Industrial Revolution. II. HOSTING DEVICE A hoisting device is used for lifting or lowering a load by means of a drum or lift-wheel around which rope or chain wraps. It may be manually operated, electrically or pneumatically driven and may use chain, fiber or wire rope as its lifting medium Example: Elevators, crane. Here the hoisting part of an EOT crane is discussed The hoisting part of the EOT crane consists of the following parts Hoist motor Gear box Drum Pulleys Wire rope Hook A hoist motor is used as a driving system for the mechanism. The motor is coupled to a gearbox. IJEDR International Journal of Engineering Development and Research ( 773

2 Figure 1 Schematic view of the hoisting device The gear box is coupled to the rope drum. The rope is wounded on the rope drum. The pulleys are arranged with 8 rope falls. At the bottom of the pulley the hook is attached with the help of a thrust bearing. III. HOSTING DEVICE Figure 2 Different views of the crane hook The inner side is called intrados and the outer side is called the extrado. According to force diagram of the hook intrado experiences more tensile force than the extrado. Hook bed diameter is given by the formula c = μ P cm Where P is the load applied in tonne c is the bed diameter μ is a constant varying from 3.8 to 7.6 Considering μ = 4.24 c = 30cm =300mm Throat of the hook is taken 0.75c =225mm d = 3.2 P + c 10 =256.2mm Using safety factor 6. W=6 x = 600,000 N IJEDR International Journal of Engineering Development and Research ( 774

3 IV. FINITE ELEMENT ANALYSIS (FEA) Solid Works 2015 precision finite element model-building tool, offers many design scenarios and mesh enhancement capabilities. Solid Works 2015 enables several design classes, including 2- and 3-D surface and solid models, beam or truss and plate/shell. Solid Works 2015 also enables engineers to build compound models having mixed element types. Solid Works 2015 provides access to Merlin Meshing Technology for automatic surface mesh enhancement or enables engineers to work directly on an FEA model surface for manual mesh enhancement. Engineers can choose tetrahedral, brick or hybrid (bricks outside and tetrahedral inside) solid FEA meshes. Solid Works 2015 s linear static and dynamic stress analysis capabilities determine stresses, displacements and natural frequencies as well as predict dynamic response to static and dynamic loading. These capabilities are highlighted throughout this brochure. Solid Works 2015 s FEA, Mechanical Event Simulation, modeling and CAD/CAE interoperability tools are designed to help engineers develop products that are more reliable and less costly to produce with faster times-to-market. To provide the best cost/benefit solution for each customer, Solid Works 2015 s High Technology Core Packages and Extenders can be purchased at special combination pricing or separately to best fit individual needs while allowing for future growth and change. The finite element method (FEM), sometimes referred to as finite element analysis (FEA), is a computational technique used to obtain approximate solutions of boundary value problems in engineering. Simply stated, a boundary value problem is a mathematical problem in which one or more dependent variables must satisfy a differential equation everywhere within a known domain of independent variables and satisfy specific conditions on the boundary of the domain. Boundary value problems are also sometimes called field problems. The field is the domain of interest and most often represents a physical structure. The field variables are the dependent variables of interest governed by the differential equation. The boundary conditions are the specified values of the field variables (or related variables such as derivatives) on the boundaries of the field. Depending on the type of physical problem being analyzed, the field variables may include physical displacement, temperature, heat flux, and fluid velocity to name only a few. (A) STRUCTURAL ANALYSIS OF CRANE HOOK BASIC STEPS OF FEA ANALYSIS FOR 1080 MILD STEEL Preprocessing: defining the problem The major steps in preprocessing are define key points/lines/areas/volumes, define element type and material/geometric properties, Mesh lines/areas/ volumes as required. The amount of detail required will depend on the dimensionality of the analysis, i.e., 1D, 2D, ax symmetric, and 3D. Solution: assigning loads, constraints, and solving Here, it is necessary to specify the loads (point or pressure), constraints (translational and rotational), and finally solve the resulting set of equations. Post processing: further processing and viewing of the results In this stage one may wish to see lists of nodal displacements, element forces and moments, deflection plots, and Stress contour diagrams or temperature maps. Step-1 Pre-processing 1) First Prepare Assembly in Solidworks ) Check the Geometry for Meshing. 3) Apply Material for Each Component. Figure 3 Geometry of Crane Hook Table Mild Steel Material Properties Yield Strength (Mpa) Component Material used Young Modulus (Gpa) Poisions Ratio Density (Kg/m 3 ) Crane Hook 1080 Mild Steel ) Create mesh. Triangle surface mesher which is programme generated. IJEDR International Journal of Engineering Development and Research ( 775

4 Fine Meshing is apply No. of Nodes: No. of Elements: Figure 4 Meshing of Crane Hook using static analysis 5) Define Boundry condition Apply Fixed Support at top portion of crane hook. Figure 5 Boundary condition of Crane Hook using static analysis Apply Force Force magnitude on hook Z-axis is 10000N. Results of Analysis Equivalent Stress for static analysis Figure 6 Force applying on Crane Hook IJEDR International Journal of Engineering Development and Research ( 776

5 Displacement Figure 7 Equivalent Stress analysis of Crane Hook Equivalent Strain Figure 8 Displacement of Crane Hook Figure 9 Equivalent Stain analysis of Crane Hook Table 2 Result of Static Analysis Material Von mises stress (MPa) Strain Displacement (mm) 1080 Mild Steel V. DYNAMIC ANALYSIS OF CRANE HOOK MODEL ANALYSIS Geometry IJEDR International Journal of Engineering Development and Research ( 777

6 Figure 10 Geometry of Crane Hook using dynamic analysis To Find Natural Frequency at Connection Region Meshing Figure 11 Connection between parts Apply Fixed Support Figure 12 Mesh Model of Crane Hook IJEDR International Journal of Engineering Development and Research ( 778

7 Results of Analysis Mode 1 Figure 13 Application of Fixed Support Mode-2 Figure 14 Total deformation of mode 1 Mode-3 Figure 15 Total deformation of mode 2 Mode-4 Figure 16 Total deformation of mode 3 IJEDR International Journal of Engineering Development and Research ( 779

8 Mode-5 Figure 17 Total deformation of mode 4 Mode-6 Figure 18 Total deformation of mode 5 Figure 5.11 Total deformation of mode 6 Results and Discussion of Modal Analysis of Crane Hook Table 3 Modal Analysis Result of Crane Hook Total Deformation of Crane Hook Mode Minimum (mm) Maximum (mm) VI. ACKNOWLEDGMENT It is indeed a great pleasure for me to express my sincere gratitude to those who have always helped me for this dissertation work. I am extremely thankful to my thesis guide Asst. Prof. Nikunj Modh, Asst. professor in Mechanical Engineering Department, VENUS International College of Technology is valuable guidance, motivation, cooperation, constant support with encouraging attitude at all stages of my work. I am highly obliged to him for his constructive criticism and valuable suggestions, which helped me to present the scientific results in an efficient and effective manner in this research. IJEDR International Journal of Engineering Development and Research ( 780

9 VII. CONCLUSION By using practical data of Crane Hook, prepared 3D CAD model for Finite Element Analysis in Solid Works From analysis result find value of von mises stress, strain and displacement (deflection) for optimize hook crane in strength and cost. Static analysis of Crane Hook gives value of von mises stress and displacement under safe condition. Dynamic Analysis of Crane Hook and performed analysis in ANSYS 14 which gives result of total deformation of structure in different six mode for Crane Hook deformation is increase with respect to change mode frequency.. REFERENCES [1] Vivek Mahadev Thakur, Vaibhav Pawar, Dr. M.D. Nadar, Sanjay Ghorpade, Sahil Patil, Study and Analysis of Crane Hook in Loading Area, IJARET, Vol. 3, Issue 1 (Jan. - Mar. 2016). [2] Jayesh Rajendra Chopda, Prof. S. H. Mankar, Design, Analysis and Optimization of Electric Overhead Travelling Crane Hook, IJTER, Volume 02, Issue 05, May [3] M.Amareswari Reddy,M.N.V Krishnaveni, B.Nagaraju, M RajaRoy, Static Analysis of Crane Hook with I- Section and T- Section using Ansys, International Journal of Engineering Trends and Technology (IJETT) Volume 26 Number 2- August [4] M.N.V Krishnaveni, M.Amareswari Reddy, M RajaRoy, Static Analysis of Crane Hook with T-Section Using Ansys, International Journal of Engineering Trends and Technology (IJETT) Volume 25 Number 1- July [5] Tejas P. Jani,Pritesh G. Biholarav, Nayan R. Solanki, Weight optimization of Crane hook having 8tons load capacity by Modifying cross section and comparison with various basic cross sections, International Journal of Innovative Research in Advanced Engineering (IJIRAE) ISSN: Issue 4, Volume 2 (April 2015). [6] Joseph Leo.A., ArutPranesh.K., Balasubramani.V., Structural Analysis Of Crane Hook, International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE) ISSN: Volume 12 Issue 3 JANUARY [7] Omkar P. Bhatkar, Arun V. Javir, Shinde Ajay Ashok, Finite Element Analysis of Crane Hook And Optimization Using Taguchi Approach., Journal of The International Association of Advanced Technology and Science, Vol. 16,March [8] Chetan N. Benkar, Dr. N. A. Wankhade, Finite Element Stress Analysis Of Crane Hook With Different Cross Sections, International Journal For Technological Research In Engineering Volume 1, Issue 9, May [9] Mr. A. Gopichand, Ms. R.V.S.Lakshmi, Mr. B. Maheshkrishna, Optimization Of Design Parameters For Crane Hook Using Taguchi Method, International Journal of Innovative Research in Science, Engineering and Technology, Vol. 2, Issue 12, December [10] Sayyedkasim Ali, Harish Kumar, Shishir Agrawal, Milin Kumar Rajurkar, Stress Analysis of Crane Hook with Different Cross Section Using Finite Element Method, International Journal of Science and Research (IJSR) ISSN (Online): Index Copernicus Value (2013). [11] Rao V. Dukkipati, M. Ananda Rao, Rama Bhat Computer Aided Analysis and Design of Machine Elements, Published by New age international limited, 2006, pages IJEDR International Journal of Engineering Development and Research ( 781