CHAPTER 6

CALCULATION OF REQUIRED DESIGN

6.1 Calculation from experimental results

In this section, we will calculate the hoop stress not only for the pulling load but also

for the braking load for the 1st layer of rope on the drum body due to the compressive

stress. Also, the pressure occurred when a loaded rope is wound onto a winch drum,

wrap by wrap; each successive wraps compress the drum in its area of contact (Refer

to section 3.4). Afterward, we will compare the hoop stress between design codes and

calculated results for both of the loading conditions.

6.2 Calculation for required drum thickness

According to the experimental results, the loaded rope tension throughout the winch

operation is decreasing from far end to near end of the drum whether there is a pulling

load or braking load applied on the drum. As a result, it is shown that the assumption

of uniform tension along the loaded rope is not supported by our experimental results.

Thus, the calculation of hoop stress in this section will be used with decreasing

pressure that acting on the drum by the rope tension due to the pulling or braking load

(Figure 6.1).

As discussed in section 3.4.3 and 3.5, the Hampe’s solution method gives more

realistic data to get an improve design. Moreover, one of the advantages of this

solution has provided a calculation on each and every wraps continuously onto the

47
winch drum; which we can observe the deflection as well as hoop stress occurring in

each positions under the respective warps on the winch drum in pulling or braking

load conditions.

As mentioned in the Chapter 3, our analysis is based on one particular design of the

winch, which is currently being used, with the following design parameters:

Drum diameter = 1000 mm

Drum Length = 1775 mm

Drum thickness = 70 mm

Steel wire rope size (diameter) = 65 mm

Applied tension load (pulling) = 200 tons = 1.96 MN

(1ton = 1000kg = 9810N)

Applied tension load (braking) = 300 tons = 2.94 MN

(1ton = 1000kg = 9810N)

Yield Stress for steel (ST 52.3) = 520 MPa

The general formula based on the Hampe’s solution [9], the hoop stress, σh is:

Nθ E E
σh =
t R
[
= w p (ξ ) + S1 F7 (ξ ) + S 2 F15 (ξ ) + S 3 F16 (ξ ) + S 4 F8 (ξ ) ] = [w]
R
(6.1)

The derivation of the above equation and the various terms are discussed in Appendix

A.

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Deflection, w, is given by,

[
w = w p (ξ ) + S1 F7 (ξ ) + S 2 F15 (ξ ) + S 3 F16 (ξ ) + S 4 F8 (ξ ) ] (6.2)

P R2
where, the ordinates of deflection line, wp is: w p (ξ ) = (1 − ξ ) (6.3)
Et

x
The non dimensional coordinate of ξ = , (6.4)
L

where (0 ≤ ξ ≤ 1): can be seen in Figure 6.1.

According to the above formulae, account is taken for the decreasing pressure applied

to the drum as illustrated in Figure 6.1.

ξ=0.25 Pressure (P)

ξ=0.75
ξ=1
ξ=0
ξ yξ=0.5 R
x
Drum
σ
D
Near end x Far end
L

Drum thickness = t Rope

Wraps
Load

Fig 6.1 Illustration of cylindrical shells affected by external decreasing pressure

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6.3 Calculated results for pulling load process

For a pulling load of 200 tons and drum thickness of 70 mm, the hoop stress exerts

onto the drum due to the load at each respective ξ positions with the number of wraps

on the drum is as shown in Figure 6.2. According to our calculated results, the highest

hoop stress occurs when the applied load is at ξ =0.8 from the near end of the drum

due to the pulling load. The details calculation of maximum hoop stress is as shown in

Appendix A. However, the highest hoop stress caused by uniform pressure has a

magnitude of 429 MPa according to Table 3.2 method III as drawn in dashed line. So

that, the percentage difference of highest hoop stress between the design codes and

our results is 19%.

Therefore, it can be accomplished that the highest hoop stress, what we called a worse

case scenario, occurs at ξ =0.8 from the near end of the drum and has a magnitude of

348.4 MPa. As a result, we can reduce certain amount of required drum thickness

compared to the design codes.

Hoop stress on the drum after pulling load applied at respective ξ position

Const
-90
ξ =0
S tres s in M P a

-180 ξ =0.25

ξ =0.5
-270
ξ =0.8
-360 ξ =1

-450
1 4 8 13 Wraps 17 22 27

Fig 6.2 Hoop stress at each respective ξ positions on the drum applied by pulling load

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6.4 Calculated results for braking load process

For a braking load of 300 tons and drum thickness of 70 mm, the hoop stress exerts

onto the drum due to the load at each respective ξ positions with the number of wraps

on the drum is as shown in Figure 6.3. According to our calculated results, the highest

hoop stress occurs again at ξ =0.8 from the near end of the drum due to the braking

load. The details calculation of maximum hoop stress is as shown in Appendix A.

However, the highest hoop stress caused by uniform pressure has a magnitude of 643

MPa according to Table 3.2, method III as drawn in dashed line. This design codes

maximum hoop stress is higher than the permissible stress level. However, our

calculated maximum hoop stress is within the permissible level. Also, the percentage

difference of highest hoop stress between the design codes and our results is 42%.

Therefore, it can be accomplished that the highest hoop stress, what we called a worse

case scenario, caused by decreasing pressure occurs again at ξ =0.8 from the near end

of the drum, whether the braking load is at that point or not and has a magnitude of

370.7 MPa. As a result, we can also reduce the certain amount of required drum

thickness compared to the design codes.

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 Hoop Stress on the drumafter braking the load at respective ξ position

0
-100
Const
-200
ξ=0
Stress (MPa)

-300
ξ=0.25
-400
ξ=0.5
-500 ξ=0.8
-600 ξ=1
-700
1 4 8 13 17 22 27
Wraps

Fig 6.3 Hoop stress at each respective ξ positions on the drum applied by
braking load

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6.5 Relationship between pulling and braking load

The main difference between these two process is the winding the rope on the drum.

In the coiling (pulling) load process, the loaded rope is wound onto a winch drum in

wrap by wrap starting from the near end to the desire position. Also, each successive

wraps compress by radial pressure inwards on to the winch drum. As for the braking

load, the unloaded rope was wound on the drum from the near end to the desired

position before the load was being applied; unlike the process of coiling the loaded

rope has been done on the drum. The comparison of loading type between these two

applications can be clearly seen on the Figure 6.4 as below.

Braking load application Pulling load application

Fig 6.4 Comparison of braking and pulling load in actual winch operation

Even though these two processes are different, the maximum hoop stress occurs in the

same position, which is ξ=0.8 from the near end of the winch drum. In addition, the

magnitude of maximum hoop stress in pulling and braking load application at ξ=0.8 is

348.4 MPa and 370.7 MPa, respectively.

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In addition, Table 6.1 shows the comparison of maximum hoop stress at each

respective ξ position between them. These calculated hoop stress will use to compute

required design.

Table 6.1 Maximum hoop stress at respective ξ position for both applications

Maximum hoop stress (MPa)

Applied load position
Pulling Load 200 tons Braking load 300 tons

ξ =0 - -

ξ =0.25 110.4 141.8

ξ =0.5 220 242

ξ =0.8 348.4 370.7

ξ =1 335.7 345.6

As can be seen in the above Table 6.1, although the load applications and magnitude

of load for each operations between the pulling load and braking load is different, the

maximum hoop stress occurs at the same position of around third quarter (ξ=0.8) from

the near end of the drum. In addition, our calculated maximum hoop stress between

pulling load and barking are comparable as the different in percentage is only a 5%;

the weight of braking load should be 1.5 times or less heavily than the weight of

pulling loads.

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6.6 Design code verses calculated results

According to the literature survey and our calculations, the DNV design guide gives

more realistic, more suitable and more easier to compute the required design of winch

drum, even though their formula are quite similar with SAA design guide. The only

difference between these two design guides is the assumed maximum permissible

stress. Therefore, the DNV design guide has been selected to compare with our

calculated results and compute the maximum hoop stress condition. The detailed

calculation of maximum hoop stress with actual operation data of DNV design code

can be seen in Chapter 3, Section 3.1. Table 6.2 shows that the comparison between

the DNV design guide and our calculated result output data.

Table 6.2 tabulates the maximum hoop stresses under the following conditions:

(a) Uniform tension of the loaded rope in Design codes and Hampe’s Solution.

(b) Decreasing tension of the loaded rope in Hampe’s Solution.

The percentage difference between the design codes and our results is 19% for the

pulling load condition and 42% for the braking load condition, respectively. These

percentage difference will be used to determine the required thickness of the improve

design.

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 Table 6.2 Comparison between DNV design code and calculated result data of Hoop Stress

Calculated result data with Percentage variation with

Hampe’s Solution Method DNV (%)
Particular DNV Code
Uniform Decreasing Uniform Decreasing
pressure pressure pressure pressure
Yield Stress in Steel ST 52.3,
520 520 520 - -
MPa

Permissible Stress in MPa 442 442 442 - -

Due to Pulling Load (200 tons)

with thickness 70 mm 430 429 348.4 0 19
(σh < σpe)

Due to Braking Load (300 tons)

with thickness 70 mm 646 643 370.7 0 42
(σh > σpe)

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6.7 Reinforced thickness for winch design

According to our calculated results, we found out that the other factor that can get a

revamping profitable design is to reinforce the thickness only in the certain area of the

winch drum, which will resist the higher compressive stress caused by the pulling or

braking load in the winch operations. As refer to the Figure 6.1 and 6.2, it can be

clearly seen that the maximum hoop stress occurred at around third quarter (ξ=0.8)

from the near end of the drum with the drum thickness of 70 mm due to the pulling

load. Moreover, the maximum hoop stress also occurred at the same position in the

braking load process (Please see details in the section 6.4).

Even though the maximum hoop stress occurred at the same position between pulling

and braking load condition, the improve design in reinforced thickness of winch drum

will emphasize only on the pulling load condition as it gives more relevant data to see

the clearer visualization of the continuous coiling. However, the suggested improve

design guide will not only compute for pulling load, but also figure out for the braking

load as well. For convenience calculations, we separated three sections as shown in

Fig 6.6 which can apply the same formulae with this Hampe theory in separated

sections for the reinforced application thickness of the drum.

As can be seen in the Figure 6.5, the graph was plotted for the 200 tons pulling

loading condition throughout the winch drum with the required thickness of 60 mm.

The details specification is as follows:

(I) Drum diameter = 1000 mm

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(II) Drum Length = 1775 mm

(III) Drum thickness = 60 mm

(IV) Diameter of Steel wire rope size = 65 mm

(V) Applied tension load (pulling) = 200 tons = 1.96 x 106 N

(VI) Yield Stress for steel (ST 52.3) = 520 MPa

(VII) D/d ratio = 15.4

(VIII) Maximum hoop stress = Please see Table 6.3 row (1)

Hoop stress on the 60 mm drum after pulling load applied at respective ξ position

Const
-90
ξ =0
S tress in M P a

-180 ξ =0.25

ξ =0.5
-270
ξ =0.8
-360 ξ =1

-450
1 4 8 13 Wraps 17 22 27

Fig 6.5 Hoop stress at each respective ξ positions on the drum applied by decreasing
pressure in uniform thickness of 60 mm

Table 6.3 Required thickness of the winch drum correlated with maximum load

Maximum weight of Hoop Stress in MPa

Thickness Permissible
loading in Tons and position
of the drum stress MPa
Pulling Braking Pulling Braking

407 437
1 60 200 300 442
nd
At ξ=0.8 (22 wrap)

400 435
2 52 200 300 442
th
At ξ=0.66 (18 wrap)

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As can be seen in the Figure 6.5 and Table 6.3, the maximum hoop stress occurs at

ξ=0.8 which is around third quarter of the 60 mm drum and has a magnitude of 407

MPa and 437 MPa for puling and braking load, respectively. However, the winch

drum had a capacity of 27 wraps of wire rope onto the full length of the drum.

According to the Figure 6.5 of pulling load application, the position of highest hoop

stresses occurred at ξ=0.8 which is around third quarter of the drum, which means it

occur between the (ξ=0.7) 19th to (ξ=0.88) 24th wraps on the drum. So that, the total of

6 wraps (from 0.7 to 0.88 ξ) which have to withstand the highest hoop stress between

382 to 407 MPa according to our calculated results. From this result, we could say

that a quarter of total wraps on the drum has compressed the maximum hoop stresses

on the drum. The rest of the wraps, other than between these wraps, withstand the

hoop stresses are 366 MPa or less.

As a result, we can reduce the thickness the drum which is from near end (ξ=0) to 18th

wraps (ξ=0.66) and 25th wraps (ξ=0.9) to far end (ξ=0). (The details illustration can be

observed in Figure 6.6 and 6.7 as below). As can be seen in Table 6.4 row (2), the

hoop stress occurred at the 18th wraps (ξ=0.66) and had a magnitude of 400 and 435

MPa in pulling and braking load, respectively for a 52 mm thickness of winch drum.

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 Pressure (P) 18th wrap (ξ=0.66)

25th wrap (ξ=0.9)

w
ξ y Section 3
x Drum R
σ
2
Section 1
D Far end
Near end L

t2=60mm thick
t1=52 mm thick

Load

Fig 6.6 Illustration of cylindrical shells affected by external decreasing pressure in

reinforced thickness of drum

Hoop stress on the variable thickness drum after pulling load applied at respective ξ position

ξ =0
-90
S tress in M P a

ξ =0.25
-180
ξ =0.5
-270 ξ =0.8

-360 ξ =1

-450
1 4 8 13 Wraps 17 22 27

Fig 6.7 Hoop stress at respective wraps on the drum applied by decreasing pressure in
reinforced thickness of drum

The above Figures 6.6 and 6.7 shows that how the reinforced thickness of the winch

drums should be fabricated and how the hoop stress exerted onto the drum in each and

every position along the winch drum.

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The detailed specification for modified winch drum in reinforced thickness is as

follows:

(I) Drum diameter = 1000 mm

(II) Drum Length = 1775 mm

(III) Drum thickness, t1 = 52 mm

(The thickness of 52 mm is from near end (ξ=0) to 18th wraps (ξ=0.66, 1170 mm) and

25th wraps (ξ=0.9, 1560 mm) to far end (ξ=0))

(IV) Drum thickness, t2 = 60 mm from 1170 (ξ=0.66) to

1560 mm (ξ=0.9)

(V) Diameter of Steel wire rope size = 65 mm

(VI) Applied tension load (pulling) = 200 tons = 1.96 x 106 N

(VII) Applied tension load (braking) = 300 tons = 2.94 x 106 N

(VIII) Yield Stress for steel (ST 52.3) = 520 N/ mm2 = 520 MPa

(IX) D/d ratio = 15.4

(X) Maximum hoop stress in 60mm = 407 MPa in pulling load

(XI) Maximum hoop stress in 52mm = 400 MPa in pulling load

(XII) Permissible stress of material = 442 MPa

(XIII) Maximum hoop stress in 60mm = 437 MPa in braking load

(XIV) Maximum hoop stress in 52mm = 435 MPa in braking load

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As above calculated thickness and their position, we can predict that the general form

of reinforced thickness into the certain area of the drum for fabrication is,

Length of the drum = L

Smaller thickness of the drum t1 is from 0 to 0.66 L and 0.9 L to L.

Larger thickness of the drum t2 is from 0.66 L to 0.9 L.

6.10 Recommended required design thickness

According to our calculated result, the following table 6.4 and 6.5 tabulate the

recommended thicknesses correlated with highest loadings for uniform thickness and

reinforced thickness, respectively.

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 Table 6.4 Recommended uniform thickness of the winch drum correlated with maximum load

Maximum weight Maximum hoop Material

Recommended of loading in Tons Stress in MPa Permissible Yield D/d Rope
Thickness of the
Sr. Pulling Braking Pulling Braking stress MPa stress Ratio Diameter
drum (mm)
load load load Load MPa

1. 70 200 300 349 375 442 520 15.3 65

2. 65 200 300 376 403 442 520 15.3 65
3. 60 200 300 407 437 442 520 15.3 65

Table 6.5 Recommended reinforced thickness of the winch drum correlated with maximum load

Recommended Maximum weight of Maximum hoop Highest hoop

Thickness of loading in Tons Stress MPa in t2 Stress MPa in t1 Material
Permissible D/d Rope
the drum (mm) Yield stress
Sr. stress MPa Ratio Diameter
Pulling Braking Pulling Braking Pulling Braking MPa
t2 t1
1. 70 60 200 300 349 375 347 377 442 520 15.3 65
2. 65 55 200 300 376 403 379 412 442 520 15.3 65
3. 60 52 200 300 407 437 401 435 442 520 15.3 65

As mentioned details in Section 6.7 reinforced thickness calculation, t2 is from 0.66 L to 0.9 L and the rest is t1 for fabrication.

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