Optimization and Analysis of Various Design for Crane Hook Using Finite Element Analysis

San, Zhen Yuan (2021) Optimization and Analysis of Various Design for Crane Hook Using Finite Element Analysis. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

Crane is material handling equipment that widely used in the industries and construction sector in current day. Among all of the component in the crane, crane hook is highly liable, which used to withstand the heavy loads attached on it. However, the crane hook is always subjected to failure due to fracture occurs in the high stress area. This is because the repeating process of loading and unloading of heavy loads or the overloading condition has weakened the crane hook from time to time. Hence, in this project, the optimization on the crane hook cross section design has been done for five different design which is round, square, trapezoidal, T-shape and I-shape. While all of the design is based from the crane hook design by Upendar (2018) that originally in triangle shape of cross section area and the safe load limit is 2000 kg. In order to determine the design that have better performance compare to original design, the model for each crane hook design has been generated with the aid of SolidWorks and performed Finite Element Analysis (FEA) with the aid of ANSYS. In the meantime, the material that applied on the crane hook is the structural steel. In the FEA, the stress analysis and the fatigue analysis of life and safety factor for the crane hook has been performed to obtain the output of each crane hook design under the boundary condition of safe load and overloading condition. From the stress analysis, the best design obtained are square shape cross section design as it improved the performance of the crane hook under the safe load with reducing the maximum Von Mises stress for 11.68% and maximum deformation for 16.43%. For the fatigue life of the crane hook is performed under the overloading condition which is in 4000 kg as the limitation of the ANSYS unable to perform this operation under the safe load condition which is 2000 kg. Therefore, the best design obtained by the fatigue life result is the square shape cross-section area which is 3.31×105 cycles and follow up by the I-shape cross-section area for 2.72×105 cycles as compare to the original design which is having fatigue life of 1.71×105 cycles. Lastly, the safety factor result is obtained under both boundary condition for better comparison on the differences of the crane hook under different condition. From the result obtained, it is noticed that the safe factor on overloading condition is lower than the safe load limit for almost 50%. Therefore, the failure of crane hook that due to overloading has been proven. As a conclusion, the square shape and I-shape cross section area is the most suitable design that having the improvement performance than the original design. Also, the safe load capacity limit for this design is under 2000 kg in term of the safe factor.