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Thin-Walled Structures
journal homepage: www.elsevier.com/locate/tws
University of Kragujevac, Faculty of Mechanical and Civil Engineering Kraljevo, Dositejeva 19, 36000 Kraljevo, Serbia
Colpart d.o.o-Beograd, irovljeva 5, 11030 Beograd, Serbia
art ic l e i nf o
a b s t r a c t
Article history:
Received 16 April 2014
Received in revised form
11 September 2014
Accepted 13 September 2014
This paper presents the analysis of local stress increases at the contact zone between the inner and outer
segments of telescopic booms of truck cranes. A portion with a relevant length was singled out of the
outer segment and a mathematical model was created describing its stressstrain state as a function of
geometrical parameters. The obtained results were veried by the nite element method as well as by
experimental testing of the truck crane TD-6/8. Comparison of results revealed high compliance between
the analytical model and the results obtained by the nite element method and experimental testing,
which conrmed all the hypotheses. The presented methodology as well as the veried analytical
expressions give guidelines for optimum design of box-like telescopic segments and other structures
with local stress increase in contact zone.
& 2014 Elsevier Ltd. All rights reserved.
Keywords:
Hydraulic truck crane
Telescopic boom
Local stress
Experimental testing
Finite element analysis
1. Introduction
The most important element for payload lifting and transport
by telescopic hydraulic truck cranes is the boom. The telescopic
boom consists of segments that retract or extend during operation.
By changing its position in space, the boom of the truck crane
transfers load onto the substructure of the crane and the vehicle
and represents its most responsible part. Reduction of dead weight
of the boom opens the possibility for increasing the payload, the
lifting speed as well as the speed of retraction and extension of the
segments.
In recent years, world manufacturers of truck cranes have been
assigning great importance to the determination of an optimum
form of the boom cross section, which would provide an increase
in bending and torsional stiffness along with the reduction of
mass. However, during overhaul and regular checks of telescopic
booms of truck cranes, certain deformations and damages in the
characteristic zone of boom segments have been noticed. That
characteristic zone is located at the contact zone between the
inner and outer segments when the inner segment is extended to
the maximum position. This fact indicates that stresses at those
zones are considerably higher than the stresses along the boom
http://dx.doi.org/10.1016/j.tws.2014.09.009
0263-8231/& 2014 Elsevier Ltd. All rights reserved.
333
Fig. 1. Model of truck crane telescopic boom: (a) generalized, (b) simplied.
334
Fig. 5. Model for analysis: (a) before disassembling the plates (b) after disassembling the plates.
4
D
x
x y
y4
where:
3
D E1 =12 1 2 the bending stiffness of the plate.
The displacement function is assumed in the form:
m x
1
wu x; y f u y sin
a
m1
Fig. 4. The portion of box-like segment loaded via two sliding pads.
2 wu
j
0;
x2 x 0
wu jx a 0;
2 wu
j
0;
x2 x a
a a2 a1 ;
m
;
b
n
;
a
c cosh b;
P 2 b c s;
s sinh b;
R1 b c 2 s 2 c 1;
R2 2 b s 1 c;
h
M a1 a2 cos a2
i
a
sin a2 sin a1 ;
m
N cos b1 cos b2 cos b3 cos b4 ;
and if it is assumed that the particular solution of Eq. (2) has the
the values of constants for the left web plate are obtained:
form:
m y
f p y K p sin
b
qco
D 2 2
2
Bl
Em c Emb
;
2Ds
Cl
Emb c Em
b;
2 D s2
Dl
Em
;
2D
where:
qco
Al 0;
335
4
q0
MN
n m 2 a2 a1
wu x; y f u y sin x
n m
The nature of supports and load transfer for the bottom ange
plate is the same as for the web plates. So, the bending equation
for the bottom ange plate has the same form (8). The displacement functions correspond to Eqs. (9) and (10), so that the solution
of the differential equation of displacement of the bottom ange
plate is obtained in the form:
wb x; y
m1
Ab Bb y chy C b Db y shy sin x
where:
12
f u y Bu y ch y C u Du y sh y K p sin y :
As this is the case with a symmetric plate which is symmetrically loaded, the change of bending moments at the ends of the
plate (for y0 and yb) can be written in the form:
1
m1
wu jy 0 0;
wu jy b 0;
m1
1
wu
D 2 jy b Em y sin x;
y
m1
Em
c1
Bu
;
2D
s
Em b
c1
Cu
;
2D
s
m1
Em
wb jy b 0;
1
2 w
D 2b jy b Emb y sin x;
y
m1
Bb
Emb c 1
;
2Ds
Cb
Emb c 1
b;
2 D s2
Db
Emb
;
2D
Dyw2u jy 0 Em y sin x;
2
Ab 0;
wb jy 0 0;
Em
;
Du
2D
Q R1 cos b
;
P R2
Emb
Em P Q cos b
;
P
where:
Q 2 D s2 K p :
10
wl x; y
m1
Al Bl y chy C l Dl y shy sin x
11
1
2 w
D 2 l jy 0 Em y sin x;
y
m1
wl jy h 0;
1
2 w
D 2 l jy h Emb y sin x;
y
m1
336
Fig. 8. Measuring points for testing the hydraulic truck crane TD-6/8.
extension of the inner segmentsection aa (Fig. 1). The dimensions of the cross section of the box-like boom segment of the
crane (Fig. 5) are: b 350 mm, h350 mm, 1 10 mm,
2 10 mm. In order to perform the analytical calculation, it is
necessary to dene the value of force between sliding pad and the
outer segment of the boom. The value of this force directly
depends on the length of extension of the inner segment, i.e. the
coordinate x (Fig. 3).
Using Fig. 7, the force Pls can be determined in relation to
extension length of the moving inner segment of the boom, i.e.
coordinate x:
P ls
13
where: the wrap angle of the rope over the upper pulley at the
top of the boom ( 901), -the coefcient of friction between the
rope and the pulley ( 0.15), Gko 0.4 kN-the weight of the pulley
blocks, Gts 4 kN-the weight of the inner boom segment [36].
While testing the truck crane TD-6/8, the following values were
established: Q8.5 kN, Lts 3750 mm, xmin 885 mm, hs 350 mm,
a2a1 250 mm, b2b1 80 mm. Based on these values and Eq. (13),
the value of the force per sliding pad is obtained: Pls 20 kN. The
value of continuous load (Figs. 4 and 5) is:
qo
P ls
a2 a1 b2 b1
14
The analytical expressions for calculation of stresses and deformations (Section 3.1) take into account only the local inuence of
pressure of the sliding pad on the outer segment of the truck crane
337
Fig. 9. Testing the hydraulic truck crane TD-6/8 (a) layout of measuring points (b) connection scheme of measuring devices.
Fig. 10. Measured stresses on the outer telescopic segment of the hydraulic truck crane TD-6/8 (a) stresses in the x direction (b) stresses in the y direction.
x;l
6 Mx
21
67 MPa y;l
6 My
21
100 MPaxy;l
6 M xy
21
1:5 MPa
e;T 90 MPa
e e;T 100 2:2 %:
338
Fig. 11. Fem model (a) density of the nite element mesh (b) load acting on the outer segment.
Fig. 13. Stress component values in the contact zone (a) normal stress in x direction (b) normal stress in y direction.
339
Fig. 16. Comparative presentation of the obtained values of deformations for each
plate in the cross section (x 88.5 cm) (a) top ange plate (b) web plates (c) bottom
ange plate.
340
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