MODELLING AND STRESS ANALYSIS OF COLUMN BRACKET FOR ROTARY JIB CRANE

Hệ thống cần trục được sử dụng vô cùng rộng rãi trong lĩnh vực kỹ thuật, vận tải. Từ đó đặt ra bài toán thiết kế hệ thống này. Cùng với cách tính toán trực quan kết hợp cùng phần mềm thiết kế 3D nổi tiếng Solidworks với module Simulation sẽ giúp ta giải quyết bài toán này

MODELLING AND STRESS ANALYSIS OF COLUMN

BRACKET FOR ROTARY JIB CRANE

Subhash N Khetre 1 , S P Chaphalkar 2 , Arun Meshram 3

1, 3

Department of Mechanical Engineering, JSPM Rajarshi Shahu COE, IIndShift Polytechnic,

Pune Maharashtra (India)

2Head of Department, Department of Automobile Engineering, Pimpri Chinchwad, Polytechnic,

Pune Maharashtra (India)

ABSTRACT

In this paper, the method of final designing of column Bracket and boom for Material handling jib crane system The basic functions are determined for certain parameters of jib cranes as yield strength, deflection of column Bracket and boom using stress analysis, displacement analysis

A requirement for movement of heavy loads which are correspondingly difficult Jib crane is design, analyze and develop from three most prevalent material handling devices They are Tower jib crane, free standing Jib crane and jib crane with trusses Among them the best design, higher strength and greater life span crane has to be designed for future work During the column Bracket and Boom analysis, the Solid Works and COSMOS is used the analysis is carried out in two load steps The total analysis time is approximately twenty two hours taken by the software

Keywords: Bracket, Jib Crane, I-Section Boom, Static Analysis, Solid Works and COSMOS

I INTRODUCTION

Today’s industry demands versatile, efficient, and cost effective equipment while at the same time providing more flexibility along with significant savings through increased productivity A jib crane can help to improve material handling efficiency and work flow Serious consideration should

be given to jib cranes for applications requiring repetitive lifting and transferring of loads within a fixed arc of rotation

The need of continual improvement in material handling technologies is a common feature of many modern engineering endeavors Engineering structures now encompass a wide range of technologies from structure development, analysis, design, testing, production and maintenance

Advances in material handling technologies have been largely responsible and major performance improvements in many engineering structures and continue to be key in determining the

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Volume 5, Issue 11, November (2014), pp 130-139

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reliability, performance and effectiveness of such structures, designing of column Bracket and boom for Material handling jib crane system

II ACTION PLAN

2.1 Selection of Crane (Phase-1)

While selecting the crane type, numbers of different factors are taken into account they are capacity, operation requirement, application, design

2.2 Selection Criterion (Phase-2)

Today’s industry demands versatile, efficient equipment while at the same time providing more flexibility along with significant savings through increased productivity A jib crane can help to improve materials handling efficiency and work flow

2.3 Work Requirement (Phase-3)

According to the below requirements free standing Jib Crane is best suitable

Table No.1: Details of Work Requirement

Sr No Particular data Details

1 Capacity 2 tons

4 Site Outside weatherized work station

5 Height of lift 6000 mm

6 Boom Length: 6000 mm

III DESIGN DETAILS OF BOOM

3.1 Selection of I-Section

Table No 2: Details of Boom in I-Section shape

Sr No Particular data Details

1 Type of Section I section fillet type

3 Material Structural Steel

4 Mass per unit length 86.9 kg/m

3.2 Selection of Material of I Section: Structural Steel (M.S.)

Table No 3: Indian standard medium weight beams Designation

Area (cm2)

Depth (mm)

Width (mm)

Web Thick

(mm)

Root Thick

(mm)

Root radius(mm)

Toe Radius (mm)

MI (cm4)

3.3 Properties of Material Steel

• Young׳s Modulus : 2×105

MPa

• Poisson׳s Ratio : 0.3

• Density : 7.85×10-6

kg/mm

• Thermal Expansion : 1.25×10-5

per oC

• Tensile yield strength : 250 MPa

• Compressive yield strength : 250 MPa

• Tensile Ultimate strength: 460 MPa

• Compressive Ultimate strength : 0 MPa

• Thermal conductivity :6.05×10-2

watt/mm oC

• Specific Heat : 434 J/kg o

C

3.4 Loads Defined

The loads acting on boom are defined as follows:

• Dead Load (DL): The weight of the beam and any other fixed item supported by the beam

• Trolley/hoist Load (HL) The weight of the hoist and any other equipment attached to the hoist

• Lifted Load (LL): The weight of the item lifted along with all associated lift devices such as slings, shackles, etc

Figure.1: Indian standard medium weight

beams with Tapered Flanges

Figure.2: Dimensioning of Free Standing Jib

Crane

3.5 Actual load carried by the boom

Table No 4: Details of Column Bracket

Actual load

Lifted Load (LL) Hoist Load (HL) Dead Load (DL)

3.6 Total load acting on the boom

This is the total load carried by the beam

= LL+HL+DL = 2000+500+243.10 = 2743.1 kg

To balance the load and to check the yield strength of I section following calculations are given

3.7 Calculations For 300×140 I-Section

To find reactions,

RX = 0 ; ∑MO = 0,

RY = 442 × 5.5 + 20 × 103 = 22431 N

Bending Moments: Bending Moment @ A

B.M at A = 0

B.M at 0 = - 20 * 103 * 5.5 – 442 * 5.5 * 103

M = 116685.25 Nm

By Using Flexure Formula,

M/I = σ / Y = E / R

(11668.25 / 8306.3 * 10-8) = (σ / 125 * 10-3)

σ = 175.59 N/m2 OR σ = 175.59 MPa

As Yield strength σ (yield)

= 250 MPa……… (ISO Std.)

Figure.3- SFD and BMD diagrams for 20 KN

Loading condition

3.8 Check the Deflection in I Section

The Deflection calculated as below

δl = (wl3/3EI) + (wl4/8EI ) For Steel, E = 210 * 109 N/m2

IV ANALYSIS RESULTS OF I-SECTION BOOM

The Static stress analysis is applied to calculation, which address the static analysis and displacement analysis resulting

Figure 4-Static stress analysis of I-Section

Boom for 20 KN loading condition

Figure 5- Static displacement analysis of I-section Boom for 20 KN loading condition

The purpose of static analysis is to insure safety of the boom and supporting structure Sustained loads are by using self weight and operating conditions In the analysis Solid Works and COSMOS software is used and the analysis is carried out in two loading steps

4.1 Analysis results of Boom

• Stress (σ): The highest calculated stress will be in the order of 108 MPa

• Deflection (δ): The maximum deflection of the end point will be in the order of 8.38149 mm

• FOS: 2.5

V DESIGN DETAILS OF COLUMN BRACKET

5.1 Design of Column Bracket

Table No 5: Details of Column Bracket

Sr No Particular data Details

The Static stress analysis is applied to calculation, which address the static analysis and displacement analysis resulting

Figure.6: Failure in shear stress of

vertical upper Pipe of Column Bracket

Figure.7: Free body diagram of forces on bracket

5.2 Design of Bracket clamper

Width b = 180 mm, Thickness t = 40 mm

In case of shearing Failure in shear stress of base plate of bracket as below:

-Therefore, design is safe Figure.8: Failure in shear stress of base

plate of bracket

VI ANALYSIS OF COLUMN BRACKET

The stress analysis is applied to calculation, which address the static analysis and displacement analysis resulting First two (2-D) dimensional brackets and Then 3-D Model of Column Bracket are created for further analysis The purpose of analysis is to insure safety of the bracket and supporting structure Sustained loads are by using self weight and operating conditions

Figure.9: Two dimensional Model of

Column bracket

Figure.10: Thee-D Model for analysis of

Column bracket

The analysis, the Solid Works and COSMOS is used the analysis is carried out in two load steps

6.1 Analysis results of bracket

• Stress (σ): The highest calculated stress will be in the order of 196 MPa

• Deflection (δ): The maximum deflection of the end point will be in the order of 2.49 mm

• FOS: 1.3

Figure.11: Static stress analysis of

Column bracket

Figure.12: Static displacement analysis of

Column bracket

VII WELDING DESIGN OF COLUMN

The designed Column Bracket consists of number of welding spots therefore size of weld are very important point as we calculated below:

7.1 Design of Seamless Steel Pipe

• Material: structural steel (0.20C 0.40Si 0.5Mn 0.035P 0.03S)

• Size: 20’’ pipe (Ø500)

• Thick: 12.5 mm

7.2 Design of welding at column bracket

d = 250 mm, b = 50 mm

l = 200 mm, τmax = 25 MPa

Figure.13: Welding to Column bracket Figure.14: Welding of bracket

The design of welding at column bracket

So , we need size and thickness,

Also, Bending stress,

Now final

Thickness t = 23 mm Size = 16 mm

7.3 Design of Welding of bracket

We are finding out welding parameters for welding different joints as below

L =1000 mm

τmax = 25 MPa

, ,

VIII RESULTS & DISCUSSIONS

8.1 Results of Boom

At first point of crane boom the load applied is 20 KN At this point load is carried with the help of a hook The maximum displacement is 8.38 mm and maximum Stress is 175 MPa near the upper portion where the assembly is done In the Figure.4 it is shown by red colour

Table No 6: Stress analysis by using analytically for 20 KN loading condition

Table No 7: Displacement analysis by using analytically for 20 KN loading condition

Table No 8: Stress analysis by using Solid Works and COSMOS for 20 KN loading condition

Table No 9: Displacement analysis by using Solid Works and COSMOS for 20 KN loading

condition

8.2 Results of Bracket Column

At this point load is carried with the help of a Boom The maximum displacement is 2.49 mm and maximum Stress is 196 MPa near the upper portion where the assembly is done In the Fig.11 it

is shown by red colour

Table No 10: Stress analysis of Column Bracket by Using Solid Works and COSMOS

Table No 11: Displacement analysis of Column Bracket by using Solid Works and COSMOS

At first during the analysis, the Solid Works and COSMOS is used the analysis is carried out

in two load steps The total analysis time is approximately twenty two hours taken by the software

IX COST ESTIMATION & PARTS LIST

All cost estimation & parts list as below in tabular form

Table No 12: Cost Estimation of Column Bracket

Sr No Name of Parts Qty Cost per piece (Rs.) Total Cost (Rs.)

3

The designed Column Bracket consists of number of parts are listed below table

Table No 13: Parts list of Column Bracket

Sr No Name of Parts Materials Weight

(kg)

Qty

2

Rope clamper plate

Mild steel 10

2.1 Rope clamper plate pin

3

3.1 Bracket pipe Structural steel 190 1 3.2 Bracket

clamper

X CONCLUSIONS

Jib Cranes vary widely in configuration, capacity, mode of operation, intensity of use, working environment The variety of forms, operating conditions, environmental factors make the design of jib cranes challenging Usually a new design need arises when existing cranes do not meet the requirements for a new application However, in most of the cases the required knowledge on configuration and structure of a jib crane can be obtained from previously accumulated technical information The technical information is generally standardized Besides that, the available jib crane components are also well standardized all over the world and suitable for computer automated design procedures Since jib Crane design procedures are highly standardized Thus it concluded that, we have selected the suitable Design and Analysis of Bracket Column for Rotary Jib Crane

XI ACKNOWLEDGEMENT

I gratefully acknowledge Department of Mechanical Engineering of RSCOE (IInd Shift Polytechnic) Tathawade, Pune (India), For technical support and providing the research facilities I would also like to thank to Dr D S Bormane, Principal RSCOE, (IInd Shift Polytechnic) Pune and Prof S Pattekari sir (DEAN) and Prof Snehal Chopade, Head of Mechanical Engineering

Department for their help and dedication toward our research and related research, also our friends for their directly & indirectly help, support and excellent co-operation

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