Marine Exam

June 14 Gondar, Ethiopia
EXAMINER’S APRROVAL PAGE
UNIVERSITY OF GONDAR
INSTITUTE OF TECHNOLOGY
SCHOOL OF MECHANICAL ENGINEERING
We certify that the project entitled “Design and Modeling of Manually Hydraulic Hand Lift Jib
Crane Machine” is written by ______________________ and ____________________________.
We have examined the final copy of this project and in our opinion; it is fully adequate in terms of
scope and design for the award of the degree of Bachelor of Engineering. We here with recommend
that it be accepted in partial fulfillment of the requirements for the degree of Bachelor of
Mechanical Engineering.
APRROVED BY:
1.
EXTERNAL EXAMINER SIGNATURE DATE
2.
INTERNAL EXAMINER SIGNATURE DATE
3.
ADVISOR SIGNATURE DATE
4.
CHAIRPERSON SIGNATURE DATE
i
ACKNOWLEDGEMENT
First of all, we would like to thank the almighty God for blessing us with strength, aptitude and
patience for successfully completing our project.
Our special appreciation goes to our advisor Mr. Ayele Hailu (Msc.) for giving us the opportunity
to work with him during this project. We have been able to compile and complete this project
report on comprehensive manner due to guidance, support and counseling that he has provided to
us.
Finally yet importantly, our sincere thanks go to each and every one who has helped and supported
us significantly indifferent stages during this project time.
ii
ABSTRACT
Jib crane is a device used for loading and unloading heavy material from trucks in the open yard
and carry them inside the shop. We have seen great challenge at the time of transportation of heavy
machine parts and equipment within and outside the workshop has been a source of concern and
needs urgent attention because of the hazard it exhibits. This negative effect on the health of the
workers which drives us to design manually hydraulic hand lift jib crane machine.
This project is mainly focused on design and modeling of manually hydraulic hand lift jib crane
machine in garages, micro and small enterprises in Ethiopia. This crane is suitable for loading and
unloading heavy material workshops with a maximum load of 3 ton (3000 kg), maximum lifting
height of 2500mm and minimum lifting height of 600mm. Beside these advantages in most
garages, micro and small enterprises in Ethiopia, this machine is not present. Instead of this they
use fork lift, overhead crane and others. So main objects of the project is to make them to use this
machine for accelerate and make easily their work activity.
To achieve these purposes, we distributed questionnaires, interviews, observation and also design
selection has been taken. Then after the responses are tabulated and analyzed using qualitative and
quantitative method of data analysis.
The main findings of the project are all most all the respondents were interested to have this
machine in their area and most of the respondent approved that this machine could help for the
employee’s safety and to accelerate and make easily the work activity in the area. This device is
very efficient with its high safety, reduces labor force, and reduces working time and workers
fatigue.
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TABLE OF CONTENT
Content page
ACKNOWLEDGEMENT .............................................................................................................. ii
ABSTRACT ................................................................................................................................... iii
TABLE OF CONTENT ................................................................................................................. iv
LIST OF FIGURES ..................................................................................................................... viii
LIST OF TABLES .......................................................................................................................... x
NOMENCLATURE AND ABBREVIATION .............................................................................. xi
CHAPTER ONE ............................................................................................................................. 1
1. INTRODUCTION ................................................................................................................... 1
1.1. Background of the Study ................................................................................................ 1
1.2. Statement of the Problem ................................................................................................ 2
1.3. Objective of the Project .................................................................................................. 3
1.3.1. General Objective: .................................................................................................... 3
1.3.2. Specific Objective ..................................................................................................... 3
1.4. Significance of the Project .............................................................................................. 3
1.5. Scope of the Project ........................................................................................................ 3
1.6. Limitation of the Project ................................................................................................. 4
1.7. Assumptions.................................................................................................................... 4
CHAPTER TWO ............................................................................................................................ 5
2. LITERATURE REVIEW ........................................................................................................ 5
2.1. Introduction to Design and Development of Product ..................................................... 5
2.1.1. Application of Cranes ............................................................................................... 7
2.1.2. Fluid Power Systems................................................................................................. 8
2.2. Current Theories and Design Done On Jib Crane .......................................................... 9
iv
2.3. Importance of Our Design in Engineering Applications .............................................. 14
2.4. Design Approach With Regard to Our Project ............................................................. 15
2.5. Available Standards Pertinent to Our Design ............................................................... 15
2.6. REASON FOR SELECTING OUR TOPIC ................................................................. 15
CHAPTER THREE ...................................................................................................................... 16
3. METHODOLOGY OF THE PROJECT ............................................................................... 16
3.1. Data Collection Method ................................................................................................ 17
3.2. Comparison of Previous Work Related to Our Project List in the Literature Review . 18
3.2.1. Design Matrix ......................................................................................................... 29
3.2.2. Summary of Literature Review ............................................................................... 31
3.3. Selection of Materials for Engineering Purposes .......................................................... 31
3.4. Design Part and Stress Analysis ................................................................................. 32
3.5. Draw Part and Assembly Drawing by using Solid Work Software and Check the
Deformation by using ANSYS Software. ................................................................................. 32
3.6. Result and Discussion ................................................................................................... 32
3.7. Cost Analysis of our Design ......................................................................................... 32
3.8. Recommendation and Conclusion ................................................................................ 32
CHAPTER FOUR ......................................................................................................................... 33
4. DESIGN ANALYSIS ............................................................................................................ 33
4.1. Data Gathering .................................................................................................................. 33
4.1.1. Interview ................................................................................................................. 33
4.1.2. Questionnaires......................................................................................................... 34
4.1.3. Observation ............................................................................................................. 34
4.2. Selection of Hydraulic Bottle Jack ............................................................................... 36
4.2.1. Oil Type .................................................................................................................. 37
v
4.3. Design Specification ..................................................................................................... 37
4.3.1. Geometrical Analysis of the Machine..................................................................... 37
4.3.2. Parameters of the Cylinder from Standard Table ................................................... 38
4.4. Design of Components of Machines ............................................................................. 43
4.4.1. Design of Horizontal Boom .................................................................................... 43
4.4.2. Design of Back Hoist Body .................................................................................... 49
4.4.3. Design of the Horizontal Frame and Base Body .................................................... 60
4.4.4. Design of Base Body .............................................................................................. 62
4.4.4.6. Deflection of Base Body ..................................................................................... 69
4.4.5. Design of Back Hoist Support ................................................................................ 70
4.4.6. Design of Horizontal Frame.................................................................................... 76
4.4.7. Design of Connecting Frame .................................................................................. 82
4.4.8. Design of Hook ....................................................................................................... 88
4.4.9. Design of Bolt and Nut ........................................................................................... 93
4.4.10. Wheel Selection................................................................................................. 104
4.4.11. Welding ............................................................................................................. 106
4.4.12. Manufacturing Process ...................................................................................... 109
CHATER FIVE ........................................................................................................................... 112
5. RESULT AND DISCUSSION ............................................................................................ 112
5.1. Results ......................................................................................................................... 112
5.2. ANSYS results for horizontal boom [input from appendix table 0:8.A] .................... 114
5.3. ANSYS results for back hoist [input data from appendix table 0:7.A] ...................... 115
5.4. ANSYS results for hook [input data from appendix table 0:8.A]............................... 116
5.5. Comparisons of ANSYS and manual result................................................................ 117
5.6. Discussion ................................................................................................................... 120
vi
CHAPTER SIX ........................................................................................................................... 121
6. COST ANALYSIS .............................................................................................................. 121
6.1. Material Cost for Manual Hydraulic Hand Lift Jib Crane .......................................... 121
6.2. Manufacturing Cost and Labor Cost ........................................................................... 123
6.3. Purchase Cost; ............................................................................................................. 123
6.4. Total Cost for Manually Hydraulic Hand Lift Jib Crane Machine ............................. 124
CHAPTER SEVEN .................................................................................................................... 125
7. CONCLUSION AND RECOMMENDATION .................................................................. 125
7.1. Conclusion .................................................................................................................. 125
7.2. Recommendation ........................................................................................................ 125
REFERENCE.............................................................................................................................. 126
DECLARATION ........................................................................................................................ 128
APPENDICES ............................................................................................................................ 129
PART AND ASSEMBLY DRAWING ...................................................................................... 143
vii
LIST OF FIGURES
FIGURE 2:1.HEAVY DUTY FOLDING WORKSHOP CRANE .................................................................. 10

FIGURE 2:3.MANUAL MOBILE MATERIAL HANDLING MACHINE ...................................................... 11
FIGURE 2:4.MOBILE JIB CRANE ...................................................................................................... 12
FIGURE 2:5.ROTATING FLOOR CRANE MACHINE ............................................................................. 12
FIGURE 2:6.CANTILEVER BEAM OF JIB CRANE. ............................................................................... 13
FIGURE 2:7.SIDE VIEW OF MOBILE FLOOR CRANE ........................................................................... 14
FIGURE 3:2.HYDRAULIC BOTTLE JACK ........................................................................................... 19
FIGURE 3:4.MANUAL MOBILE MATERIAL HANDLING MACHINE ...................................................... 21
FIGURE 3:5.MOBILE JIB CRANE ...................................................................................................... 22
FIGURE 3:6.ROTATING FLOOR CRANE MACHINE ............................................................................. 24
FIGURE 3:7.WORKING PRINCIPLE OF HYDRAULIC JACK .................................................................. 25
FIGURE 3:8.CANTILEVER BEAM OF JIB CRANE. ............................................................................... 26
FIGURE 3:9.SIDE VIEW OF GENERAL ASSEMBLY ............................................................................. 27
FIGURE 4.1:1.INTERVIEWING FROM DIFFERENT COMPANY ............................................................. 33
FIGURE 4.1:2.OBSERVATION OF MANUALLY HYDRAULIC HAND LIFT FIXED JIB CRANE FROM JOVANI
GARAGE ................................................................................................................................. 34
FIGURE 4.1:3.OBSERVATION OF BARANCO FROM JOVANI GARAGES ............................................... 35

FIGURE 4.1:4.3D VIEW OF THE MACHINE ........................................................................................ 37
FIGURE 4.1:5.FRONT VIEW OF OUR MACHINE ................................................................................. 38
FIGURE 4.1:6.WHEN THE CYLINDER IS RETRACTED AND EXTRACTED TRIANGLE............................. 39
FIGURE 4.1:7.WHEN THE CYLINDER IS RETRACTED ........................................................................ 39
FIGURE 4.1:8.WHEN THE CYLINDER IS AT NORMAL POSITION ........................................................ 40
FIGURE 4.1:9.WHEN THE CYLINDER IS EXTRACTED ....................................................................... 41
FIGURE 4.1:10.TRIANGLE OF BACK HOIST BODY WITH BASE BODY (∆ACO) .................................. 41
FIGURE 4.1:11.TRIANGLE OF BACK HOIST BODY WITH HORIZONTAL FRAME AND BACK HOIST
SUPPORT (∆AHO) ................................................................................................................... 42
viii
FIGURE 4.1:12.FBD OF BOOM AT NORMAL POSITION ..................................................................... 42
FIGURE 4.1:13. 3D VIEWS OF HORIZONTAL BOOM........................................................................... 44
FIGURE 4.1:14.FBD OF BOOM WHEN THE CYLINDER AT EXTRACTED POSITION .............................. 44
FIGURE 4.1:15.3D VIEWS OF BACK HOIST BODY ............................................................................. 50
FIGURE 4.1:16.FBD OF THE HOIST BODY ....................................................................................... 51
FIGURE 4.1:17.FRONT VIEW OF MACHINE ....................................................................................... 60
FIGURE 4.1:18.TOP VIEW OF MACHINE ........................................................................................... 61
FIGURE 4.1:19.3D VIEW OF BASE BODY .......................................................................................... 62
FIGURE 4.1:20.FBD OF BASE BODY ............................................................................................... 63
FIGURE 4.1:21.3D VIEW OF BACK HOIST SUPPORT .......................................................................... 70
FIGURE 4.1:22.FBD OF BACK HOIST SUPPORT ................................................................................ 71
FIGURE 4.1:23.SIDE VIEW OF BACK HOIST SUPPORT ....................................................................... 71
FIGURE 4.1:24.3D VIEW OF HORIZONTAL FRAME............................................................................ 77
FIGURE 4.1:25.FBD OF HORIZONTAL FRAME ................................................................................. 77
FIGURE 4.1:26.3D VIEW OF CONNECTING FRAME ........................................................................... 83
FIGURE 4.1:27.FBD OF BASE BODY ............................................................................................... 83
FIGURE 4.1:28.3D VIEW OF HOOK................................................................................................... 88
FIGURE 4.1:29.FBD HOOK ............................................................................................................. 90
FIGURE 4.1:30.3D VIEW OF BOLT 2 ................................................................................................. 93
FIGURE 4.1:31.3D VIEW OF NUT 1 .................................................................................................. 93
FIGURE 4.1:32.HEXAGONAL HEADED BOLT WITH A NUT AND WASHER IN POSITION [14] ............... 98
FIGURE 4.1:33.3D VIEW OF FRONT WHEEL ................................................................................... 104
FIGURE 4.1:34.3D VIEW OF REAR CASTER WHEEL ........................................................................ 105
FIGURE 4.1:35.THE CROSS-SECTION OF A WELDED BUTT JOINT .................................................... 109
ix
LIST OF TABLES
TABLE 3:1.COMPARISON CRITERIA FOR EACH MODEL .................................................................... 29
TABLE 4.1:1.INTERPRETATION OF INTERVIEW AND DISTRIBUTED QUESTIONNAIRES ...................... 35
TABLE 4.1:2.STANDARD TABLE OF THE RELATION BETWEEN EQUIVALENT LENGTH (L) AND ACTUAL
LENGTH (L) ............................................................................................................................ 57
TABLE 4.1:3.STANDARD VALUE OF “C” ......................................................................................... 58

TABLE 4.1:4.VALUE OF CRUSHING STRESS (ΣC) AND RANKINE’S CONSTANT (A)............................ 59
TABLE 4.1:5: STANDARD DIMENSIONS OF CRANE HOOK [13] ....................................................... 89
TABLE 4.1:6.STANDARD TABLE OF FRONT WHEEL ........................................................................ 105
TABLE 4.1:7.STANDARD TABLE OF REAR WHEEL .......................................................................... 106
TABLE 5:1.RESULT OF ALL PARTS ................................................................................................ 113
TABLE 6:1.MATERIAL COST OF EACH COMPONENT ....................................................................... 121
TABLE 6:2.MANUFACTURING & LABOR COST OF EACH MATERIAL ............................................... 123
TABLE 6:3.PURCHASE COST ......................................................................................................... 124
TABLE 0:1.A. TYPICAL MECHANICAL AND PHYSICAL PROPERTIES FOR ENGINEERING METALS ..... 129
TABLE 0:2.A. STANDARD TABLE OF HYDRAULIC CYLINDER ......................................................... 130
TABLE 0:3.A. DIMENSIONS AND CROSS-SECTIONAL PROPERTIES SQUARE HOLLOW SECTIONS ..... 131
TABLE 0:4.A. SPECIFICATION FOR STEELED IN MILLIMETER SERIES SCREWS AND BOLTS .............. 133
TABLE 0:5.A. BASIC DIMENSIONS FOR SQUARE THREADS IN MM (NORMAL SERIES) ACCORDING TO
IS: 4694 – 1968 (REAFFIRMED 1996)................................................................................... 133
TABLE 0:6.A. INPUT DATA FOR ANSYS RESULTS OF HORIZONTAL BOOM .................................... 135
TABLE 0:7.A. INPUT DATA FOR ANSYS RESULTS OF BACK HOIST BODY ....................................... 137
TABLE 0:8.A. INPUT DATA FOR ANSYS RESULTS OF BACK HOIST BODY ....................................... 140
x
NOMENCLATURE AND ABBREVIATION
Symbol Full name Unit
Le Cylinder extracted length mm
Lr Cylinder retracted length mm
θ1 Cylinder extracted angle °
θ2 Cylinder retracted angle °
kg Kilogram kg
UK United kingdom -
Max Maximum -
Min Minimum -
TÜV Technical Control Board -
mm Millimeter mm
g Gravity m/s 2
kN Kilo newton kN
Lb boom length mm
FBD Free body diagram -
@ At -
W Weight kN
Ap Area of the piston mm2
D Bore diameter mm
xi
Fp Force acting on the piston kN
P Working pressure of the piston. MPa
E Young’s modulus of the elasticity GN/m2
G Shear modules MN/m2
σt Tensile strength MN/m2
σy Yield strength MN/m2
ρ Density kg/m3
3d Three dimensional view -
I Moment of inertia kNmm
M bending Moment kNmm
m mass Kg
σb bending stress, MN/m2
F. s Factor of safety -
σd Direct stress N/m2
τ Shear stress Mpa
σp principal stress Mpa
ymax Maximum deflection Mm
Vmax Maximum shear stress kN
l effective length of the back hoist body mm
xii
K The least radius of gyration of the section mm
Wcr Crippling load by Rankine’s formula kN
Wc Ultimate crushing load for column kN
WE Crippling load obtain by Ewer’s formula kN
σc Crushing yield stress Mpa
a Ranking constant -
A cross section area of the column mm2
Ltb total length of the base body mm
LT The total length of the horizontal frame mm
b Base of the section mm
h Height of the section mm
t Thickness of the section mm
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DESIGN AND MODELING OF HYDRAULIC HAND LIFT JIB CRANE | 2010 E.C
CHAPTER ONE
1. INTRODUCTION
1.1. Background of the Study
Jib crane is suitable for loading and unloading heavy material from trucks in the open yard and
carry them inside the shop.
Established in 1869, The David Round Company is one of the oldest and most experienced hoist
manufacturers in the world. The David Round Company specializes in the production of standard
handling products such as chain hoists, jib cranes, winches, and tractor drives. We offer cutting-
edge efficiency solutions like engineered wire rope hoists, stainless steel chain hoists, and jib crane
motorization kits [1].
Manual hydraulic hand lift mobile floor crane with extendable boom in 1, 2 and 3ton capacities
and vertical height reaching up to 4 meters. These are also provided base in the rear for putting
counter weight, in case the boom is extended beyond the base wheels. These are extensively used
in engineering workshops for loading and unloading jobs on the machine tools where there is no
provision of an overhead crane or it is busy else-where in repair garages these are required for
handling engines and its parts. These are equipped with high precision hydraulic cylinder and hard
chrome plated Ram which provides upward thrust to the boom while lifting. The lowering is
effected by feather touch foot pedal or wheel valve. Lowering is hydraulically cushioned to avoid
jerks. The base frame can be wide enough to take the load between the two outstanding legs. All
the 4 number wheels are two ball bearings each. A single handle will pull, push and steer the
wheels as well as operate the pump for lifting which is a great advantage in our design. The jib
crane is also available in electro hydraulic lifting and battery hydraulic lifting version in case of
heave loads or more frequency of operations lifting done by a hand lever mounted on power pack
place on the front of jib crane [2].
The crane for lifting heavy loads was invented by the Ancient Greeks in the late 6th century BC.
The archaeological record shows that no later than c.515 BC distinctive cuttings for both lifting
tongs and Lewis irons begin to appear on stone blocks of Greek temples. Since these holes point
at the use of a lifting device, and since they are to be found either above the center of gravity of
UOG/IOT/SCHOOL OF MECHANICAL ENGINEERING 1 THESIS PROJECT

the block, or in pairs equidistant from a point over the center of gravity, they are regarded by
archaeologists as the positive evidence required for the existence of the crane [3].
The introduction of winch and pulley hoist then leads to a widespread replacement of ramps as the
main means of vertical motion. For the next two hundred years, Greek building sites witnessed a
sharp drop in the weights handled, as the new lifting technique made the use of several smaller
stones more practical than of fewer larger ones. In contrast to the archaic period with its tendency
to ever increasing block sizes, Greek temples of the classical age like the Parthenon invariably
featured stone blocks weighing less than 15-20 metric tons. Also, the practice of erecting large
monolithic columns was practically abandoned in favor of using several column drums [4].
Although the exact circumstances of the shift from the ramp to the crane technology remain
unclear, it has been argued that the volatile social and political conditions of Greece were more
suitable to the employment of small, professional construction teams than of large bodies of
unskilled labor, making the crane more preferable to the Greek polis than the more labor-intensive
ramp which had been the norm in the autocratic societies of Egypt or Assyria [5].
The first unequivocal literary evidence for the existence of the compound pulley system appears
in the mechanical problems attributed to Aristotle (384–322 BC), but perhaps composed at a
slightly later date. Around the same time, block sizes at Greek temples began to match their archaic
predecessors again, indicating that the more sophisticated compound pulley must have found its
way to Greek construction sites by then [5].
1.2. Statement of the Problem

Since manufacturing company are needed to create methods that can be accelerating their work
activity which reflect to get better production and life efficiency.
Sound professional best practice aimed at workshops injury and accident prevention and reduction
ensures the utilization of appropriate tools for any job. As we observed in UOG work shop, the
garages, and micro and small enterprises in Ethiopia, Motor vehicle repair and maintenance often
require the lifting of the entire vehicle or sub-assembly part of it or the lifting up and down of its
heavy components. Also in other industries and welding shops, there are items and repairs which
need the employment of shop cranes. The lack of shop crane utilization in our industries and

automobile repair shops not only leads to injury and accident but also to poor repair and
maintenance occurrence. They are practically use machines like overhead crane, forklift, and other
kind of cranes. Even though, those machines are working on rigid condition (i.e. fixed or not
having a roller) and the structure we have seen in a company’s are exposed to stress and fracture.
So this was the reason, which drives as to design of manually hydraulic hand lift jib crane machine.
1.3. Objective of the Project

1.3.1. General Objective:
The general objective of this project is to design and modelling of manually hydraulic hand lift jib
crane machine with a maximum lifting capacity up to 3 tons, minimum and maximum height of
600mm and 2500mm respectively.
1.3.2. Specific Objective:
 Design the components of manual hydraulic hand lift jib crane machine.
 Selection of proper material for our manufacturing process.
 To save time and reduce cost of material handling equipment.
 To minimize human load carrying risk.
 Select standard parts such as hook, wheel and hydraulic bottle jack.
 Check the deformation by using ANSYS software.
1.4. Significance of the Project

Manually hydraulic hand lift Jib crane machine is a manual mobile material handling machine
suitable for indoor and outdoor services and it can be handle by the single person. Jib crane, a free
standing or portable jib crane is an economical solution for moving materials on working and/or
for use an auxiliary lifting device under an overhead crane. In addition to this, this machine is
mechanical in nature and does not pollute the environment. Finally, it is a good opportunity for
small and micro enterprises to take advantage by utilizing this machine because one of the current
developmental strategies in Ethiopia is to support these enterprises.
1.5. Scope of the Project

The project is conducted on the title “design and modelling of manual hydraulic hand lift jib crane
machine” and mainly focusing on small and micro enterprise and garages in Ethiopia.

This project is started with literature review on the product specification in order to satisfy the
project objectives. After obtaining the product specification, this project is done based on the scope
listed below;
 Design of jib crane includes structural design, mechanical design and electrical equipment
design part. But in our case, we focused on mechanical design and structural design of jib
crane, such as material selection, horizontal boom design, back hoist body design, bolt and
nut design, etc.
 Completing the project with specified time.
 The machine uses in labeled land and friction less surface.
1.6. Limitation of the Project

 Shortage of time to limit the work.
 The data’s and observations are taken from few companies.
 We observe problem of the machine only in UOG work shop and Gondar town not in
other town of Ethiopia.
 Internet connection problem to limit the work.
1.7. Assumptions
We are gather different information from different company through interviewing to be maximum
and minimum weight of the material is 3000kg and 200kg respectively for moving, loading and
unloading purpose. So our design analysis depends on by taking maximum weight of material to
be lifted.
By reading different journals and researchers of literature review (maximum height = 2445 mm
minimum height = Floor level) we take maximum lifted height to be 2500mm in our design
analysis and from standard table of cylinder for three ton read from the appendix table Maximum
height extracted position (Le ) =1176.274 mm, (𝜃1 = 65°), the maximum lifting height is 2500mm
and Minimum height retract position (Lr ) =668.274 mm (𝜃2 = 50°) and the minimum lowering
height is 600mm. Because of the extracted position is greater than retracted position ( 𝜃1 < 𝜃2 ).
And also the length of the boom is 1250mm.

CHAPTER TWO
2. LITERATURE REVIEW
Crane in ancient times applied during the Roman Empire, when construction activity soared and
buildings reached enormous dimensions. The Romans adopted the Greek crane and developed it
further. There are also two surviving reliefs of Roman tread wheel cranes, with the Haterii
tombstone from the late first century AD being particularly detailed. The simplest Roman crane,
the trespasses, consisted of a single beam jib, a winch, a rope, and a block containing three pulleys.
2.1. Introduction to Design and Development of Product

Product design and development is the set of activity beginning with the perception of market
opportunity and ending in the product. It is an interdisciplinary activity requiring contribution from
nearly all the function of a firm however three function are almost always central to product and
design development project those are, marketing, design and manufacturing (Hayes, Robert,
Steven C., New York, 1988).
A generic development process is a sequence of steps that transforms asset of inputs into asset of
out puts and it is the sequence of steps or activity which an enterprise employs to conceive, design,
and commercialize product. Therefore it is useful because of the following reason these are quality
assurance, coordination, planning, management and improvement. In the product design and
development there are six phases. These phases are as follows (Cooper, Robert’s, MA, 2001):
Phase 0.plannig: this phase is begins with corporate strategy and includes assessment of
technology developments and market objectives.
Phase1.concept development: it adscription of the form, function, and feature of product and is
usually accompanied by asset of specification, an analysis of competitive product, and an
economic justification of the product.
Phase 2.system level design: the output of this phase is geometry layout of the product, functional
specification of each of the product subsystem and preliminary process flow diagram for the final
assembly process.

Phase 3.detail design: it includes the complete specification of the geometry, material and
tolerance of all of the unique part in the product and the identification of all of the standard parts
to be purchased from supplier.
Phase 4.testing and refinement: this phase is involves the construction and evaluation of multiple
preproduction versions of the product.
Phase 5: production ramp-up: at this phase the product is made using the intended production
system. The purpose of the ramp up is to train the work force and to work out any remaining
problems in the production processes. Product planning process takes place before product
development project is formally approved, before substantial resources are applied and before the
larger development team is formed. Product planning is an activity that considers the portfolio of
projects that an organization might pursue and determines what subset of these projects will be
pursued over what time period (Christensen, 1997).in general there are four type of product
development projects, those are, new product platforms, derivatives of existing product platforms,
incremental improvements to existing product and fundamental new products. There are many
methods to help managers balance an organization portfolio of development project. so that
managers may consider the strategic implications of their planning decision(Cooper et
al.(2001))one particularly useful mapping, suggested by Wheelwright and Clark(1992),plots the
portfolio of projects along two specific dimension.
Machine Design is the creation of new and better machines and improving the existing ones. A
new or better machine is one which is more economical in the overall cost of production and
operation. The process of design is a long and time consuming one. From the study of existing
ideas, a new idea has to be conceived. The idea is then studied keeping in mind its commercial
success and given shape and form in the form of drawings. In the preparation of these drawings,
care must be taken of the availability of resources in money, in men and in materials required for
the successful completion of the new idea into an actual reality. In designing a machine component,
it is necessary to have a good knowledge of many subjects such As Mathematics, Engineering
Mechanics, Strength of Materials, Theory of Machines, Workshop Processes and Engineering
Drawing. Historically, a variety of factors, both internal and external to a company have influenced
its product design goals.

Material Handling is the movement, storage, control and protection of materials, goods and
products throughout the process of manufacturing, distribution, consumption and disposal. The
focus is on the methods, mechanical equipment, systems and related controls used to achieve these
functions. Hydraulic cranes are an important part of the material handling equipment’s. The
hydraulic cranes that are being used work on electrical supply or manual power.
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.
2.1.1. Application of Cranes

Cranes exist in an enormous variety of forms – each tailored to a specific use. Sometimes sizes
range from the smallest jib cranes, used inside workshops, to the tallest tower cranes, used for
constructing high buildings. For a while, mini - cranes are also used for constructing high
buildings, in order to facilitate constructions by reaching tight spaces. Finally, we can find larger
floating cranes, generally used to build oil rigs and salvage sunken ships.
These days hydraulics principle is being used extensively in material handling processes through
cranes. Depending on the loads to be handled and the operations to be performed there are different
types of cranes like Crawler Cranes, Truck Cranes, and Floor Cranes.
Hydraulic Crawler cranes are used for picking and moving huge amount of loads. Generally loads
are kept in containers for Bulk loading.
Hydraulic truck cranes have good flexibility with high load carrying capacities. Hydraulic
workshop foldable crane are used in industries for moving small to medium sized materials from
one place to other. The load carrying capacity can vary from half ton to 2 ton or more.

2.1.2. Fluid Power Systems

The transmission of power by fluid power system is most convenient and highly efficient. Due to
this, the present conventional power transmission system are being replaced and changed over to
fluid transmission system. In this prime mover supplies mechanical energy to a pump which is
used to pressurize fluid. Then the pressurized fluid is transmitted to different parts of the system
through special piping’s or tubing’s. At desired places pressure energy is converted back to
mechanical energy by the devices called actuators consisting of hydraulic cylinders, hydraulic
motors etc. Since the power is transferred through the fluid as a medium, such a system is called
as fluid power system.
2.1.2.1. Components of Fluid Power System

1. Hydraulic Power Pack: A hydraulic power pack is the device used to supply pressurized
fluid to the piston cylinder so as to extend or contract it. It is required to move the arm in
the intended direction. A hydraulic power maybe electrically powered or manually
powered.
2. Base: Base is the bottom most part of the hydraulic floor crane which supports all the other
parts. It should be designed so as to sustain the weight of the crane as well as the weight to
be lifted.
3. Support Column: Support column is fixed to the base and it supports the arm of the crane,
also the cylinder is hinged to it. In the rotary design of crane the support column is
connected to the output gear through which rotation force is transmitted, it also contains
the bearings. Support column can be put vertically on the base or can be inclined at an
angle with the base for better support.
4. Arm: It is fixed to the upper end of the support column and a hook is fixed to the other end
of the arm to lift the weight. The arm is crucial in design as it takes the bending loads and
may bend due to weight. For variable load distribution, the arm can be split up into two
parts that can slide in each other.

5. Piston Cylinder: Hydraulic floor crane has a piston cylinder arrangement to provide the
movement of the arm. The maximum and minimum height of the arm is achieved by the
piston cylinder. Thus it acts as an actuator to do the intended work.
6. Steer wheel: It is rear wheel of the hydraulic floor crane. It is situated near the steering so
the name steer wheels. These are responsible for the turning of the crane.
7. Load wheels: It is the front wheel of the hydraulic floor crane. The weight to be lifted acts
downward where the load wheels are mounted. Thus they are called as load wheels and are
to be designed so as to sustain the load lifted.
8. Hook: It is attached to the arm of the hydraulic floor crane. It is used to lift the weight. The
design of hook is also crucial. Standard hooks are available in the market for different
loads.
 Identifying customer need is an integral part of the larger product development process
and is most closely related to concept generation, concept selection, competitive
benchmarking and the establishment of product specification.
2.2. Current Theories and Design Done On Jib Crane

These days hydraulics principle is being used extensively in material handling processes through
cranes. Depending on the loads to be handled and the operations to be performed there are different
types of cranes like Crawler Cranes, Truck Cranes, and Floor Cranes.
Hydraulic Crawler cranes are used for picking and moving huge amount of loads. Generally loads
are kept in containers for Bulk loading.
Hydraulic truck cranes have good flexibility with high load carrying capacities.
Hydraulic workshop foldable crane used in industries for moving small to medium sized materials
from one place to other. The load carrying capacity can vary from half ton to 3 ton or more. There
are so many theories and designs are done by many researchers and companies on design and
developing of jib crane. We have listed them with their pictures below;
1. The UK business market LTD [6], “design and manufacturing of heavy duty Folding
Workshop Crane machine (2018)”. This paper presents for self-standing and completely
mobile when in the folded position, saving valuable workshop space. Heavy duty 3 position

telescopic jib double acting pump unit Swivel hook with safety catch Pressure relief valve to
prevent overloading Self standing on 4 wheels. And it has capacity of 1-2 tons only and Max
Height = 2445 mm Min Height = Floor level. But this crane is expensive due to the two
extra wheel and have minimum load capacity relatively to our design.
Figure 2:1.Heavy duty folding workshop crane
2. Nationwide industrial supply [7], “design and manufacturing of beech counterweighted crane
machine (2018)”. This paper stands without front legs, thus eliminating interference with load
lifting or equipment. Maximum height of 2100mm and minimum height of 20mm at full
capacity of load lifting of 2000lbs at a counter weight of 1000lbs with a price of $7059.6 And
Safety swivel hook is attached directly to extension boom and Safety bypass relief valve is
standard to prevent dangerous overloading. For ease of movement, crane has phenolic wheels
with roller bearings. But this type of crane is expensive, needs extra load for safety,
minimum height and have minimum load capacity relatively to our design.

3. Rockwell Hoisto Cranes Private Limited [8], “design and manufacturing of manual mobile
material handling machine (2018)”. This paper stands in suitable for Indoor and Outdoor
services. It is the basic requirement in all the motor garages and machine shop for loading and
unloading of the engines and materials from the vehicles. But it is tedious during operation
and it is costly due to rope, pulley gear mechanism and teeth wear.
Figure 2:3.Manual mobile material handling machine
4. Selby Engineering and Lifting Safety LTD [9], “design and manufacturing of mobile jib crane
machine (2018)”. This paper was developed in collaboration with users to ensure that it is
practical manual handling aid, approved by the Technical Control Board (TÜV) in Germany
this is a top quality piece of lifting equipment as totally unique in its design. The crane features
easy handling and increased work place safety through high quality products standard. It is a
collapsible unit which enables easier transportation through low headroom areas such as
doorways and it rotate 360 degree to lift load. This design uses generator or motor for its
loading system due to this it may have unwanted noise and high output cost. Also it uses
technical control leads to increase its manufacturer cost.

Figure 2:4.Mobile jib crane
5. Asmita Jadhav, B.E. Mechanical (Pune University) [10], “Design and development of Rotating
Floor Crane (2018)”. This paper stands for working with Applied Hydrotech, PuneMember of
Entrepreneurs Club Pune. City-Pune, India. This crane needs gear box to transmit motion
and power from hand to the rotating column and the structure is exposed to stress and
fracture.
Figure 2:5.Rotating floor crane machine

6. Chaitra C. Danavatimath, Prof. H. D. Sarode (P.G.student.Dpartment of Mechanical
Engineering (2017)) [11], “Finite Element Analysis and Optimization of Jib Crane Boom”.
This paper stands for structural analysis of cantilever beam of jib crane includes an

investigation of the stresses, deflections, shear capacity and lateral-torsional buckling behavior
of regular I Section Cantilever Beam of jib crane subjected to UDL (self-weight) and
concentrated load at free end. The beam fails due to Lateral Torsional buckling. Different
shapes of cantilever are proposed in this study with different cross-sections, web shapes and
materials. FEA and experimental study are carried out for regular and proposed beam to
calculate and validate results. Thickness of web and flange is constant for all specimens with
length 2.54 and tested for 500kg load lifting capacity. Structural analysis is done to examine
the influence of the section dimension due to point load at the free end and uniformly
distributed load on cantilever. Using the study it is observed that not only the web thickness,
but also the shape of web and sectional cross section of cantilever beam influences the
resistance to lateral torsional buckling and bending. a
Figure 2:6.Cantilever beam of jib crane.
7. Okolie Paul Chukwulozie et al [12], “Design and Analysis of a mobile floor crane (2015)”.
Design and fabrication of a mobile floor crane equipped with a facility to lock the load at any
level as a special feature, to tackle the issue of failure due to static load. The mobile crane is

designed to bear a maximum load of about 1000 kg and a maximum height of two meter,
with a counter weight of 2.6 KN which gave the crane a 3.034 factor of safety [11]. But the
counter weights at the rear base for cases where the boom is extended beyond the front
base wheel to balance the weight of the material to be lifted and the load locking device
highly stressed.
Figure 2:7.side view of mobile floor crane
2.3. Importance of Our Design in Engineering Applications

 Important of manual hydraulic hand lift jib crane in engineering application
 Our design is used for picking and moving huge amount of loads from one place to
another place.
 Our design have good flexibility with high load carrying capacities.
 Our design is quite easy to operate.
 We can use the hydraulic bottle jack for multiple purpose in this design. For
example it can be used for picking, carrying and moving any loaded object up to
this design maximum loading capacity (3 ton).
 It can reduce the risks of human beings from carrying high load object such as
disk prolapse.

 It can’t use motor or generator power for moving purpose so that it helps to
reduce the output cost.
2.4. Design Approach With Regard to Our Project

 We collect the necessary Data through interview, questionnaires and observation.
 We select proper material for each parts of the machine.
 We design parts and stress analysis.
 We estimate cost analysis.
 We draw parts and assembly drawing by using solidwork software.
 We check the deformation of each parts by using ANSYS software.
2.5. Available Standards Pertinent to Our Design

 Standards pertinent to our design are:
 Hydraulic bottle jack
 Wheel
 Crane hook
2.6. Reason for Selecting Our Topic

 The reason we select this topic is that:
 The UOG workshop have already finished the building and it’s waiting for the
availability of necessary machines for the workshop so that we selected this design to
solve the problems of picking, carrying and moving any loaded objects from one
place to other place in a safe way, since this service are not given adequately by the
product supply company that means it may give the service of putting loaded objects
to one place but not moving to the place we needed.
 In addition to this, our design can also reduce the problems of picking, carrying and
moving loaded objects on garages and other small enterprise in our country.
 We can use the machine in the workshop without disturbing those taking services in
the workshop (students) and workshop lab assistance.
 It can also reduce risk of polluting the environment from smoke, since it operates
hydraulically, it can’t release any smoke.

CHAPTER THREE
3. METHODOLOGY OF THE PROJECT

Methodology is the basic part of any scientific research because it gives detail about the data. Thus
from this process on wards we will be able to get our design requirements and start designing
accordingly.
Need or Aim
( )
Fig. design flow chart
To come up with adequate solution for the problem what we proposed; as possible as we could we
were following an exact technical procedures throughout this paper according to what we gain
from mechanical engineering knowledge back ground.

In order to conduct this study, methods and procedures have great contribution for reaching the
final result of the paper. The methods used are discussed below in detail.
3.1. Data Collection Method

 Interview: in order to strengthen the design, we will use this method. So some
employees that are concern to our project will involve in responding the interview.
 Observation: in order to check and to be sure our project this method is very
crucial. During this observation, we will observe in person in the place what kinds
of machines are present and how they have used the machines.
 Questionnaire: in order to achieve the purpose of this project we will distribute
questioners for concerned persons.
Data collection method
Primary data Secondary data
Example: read from

Quantitative data Qualitative data previous journals,
researches, internet, etc.
v
Survey Experiments Focus group
v
 Personal Mechanical Individual depth interview
interview observation
 Companies Human observation
 Email Simulation
Case studies
Figure: data collection method flow chart

3.2. Comparison of Previous Work Related to Our Project List in the

Literature Review
1. MODEL -1
 Component of model 1
 Bolt and nut  unit Swivel hook with safety
 Boom catch
 Hydraulic jack  Pressure relief valve to prevent
 Frame overloading
 Double acting pump  Self-standing on 4 wheels
 Operating instructions of model 1
1. Insert the jack handle into the hole of the handle socket.
2. Make sure the saddle is correctly positioned. To prevent damage to the jack, do not
move the jack while the handle is intact in the socket.
3. To raise load, use one hand to hold the front part of the handle, and use the other hand
to turn at the rear end of the handle clockwise.
4. To lower load, use one hand to hold the front part of the handle and use the other to
turn at the rear end of the handle counterclockwise slowly
 Working principle of model 1
Hydraulic jack works on the principle of ―Pascal‘s law.
When the handle is operated, the plunger reciprocates then the oil from the reservoir is sucked

into the plunger cylinder during upward stroke of the plunger through the suction valve. The oil
in the plunger cylinder is delivered into the ram cylinder during the downward stroke of the
plunger through the delivery valve.
This pressurized oil lifts the load up, which is placed on top plate of the ram. After the work is
completed the pressure in the ram cylinder is released by unscrewing the lowering screw thus the
pressure releases and the ram is lowered, then the oil is rushed into the reservoir. It consists of
plunger cylinder on one side and ram cylinder on the other side. These two cylinders are mounted
on base which is made of mild steel. Plunger cylinder consists of plunger which is used to build
up the pressure by operating the handle. Plunger cylinder consists of two non-return valves i.e. one
for suction and other for delivery. Ram cylinder consists of ram which lifts the load. The ram
cylinder connected to delivery valve of plunger cylinder. It is also consists of lowering screw this
is nothing but a hand operated valve used for releasing the pressure in the ram cylinder for get
down the load.
Figure 3:2.hydraulic bottle jack
 Advantage of model 1
 Heavy duty Folding Workshop Crane
 Use in business market

 It is self-standing
 completely mobile when in the folded position,
 Saving valuable workshop space.
 Heavy duty 3 position telescopic jib
 Double acting pump unit Swivel hook with safety catch
 Pressure relief valve to prevent overloading Self standing on 6 wheels.
 Disadvantage of model 1
 It has capacity of 1-2 tons only
 Crane is expensive
 Have minimum load capacity relatively to our design.
 It has 6 wheels.
2. MODEL -2
 Components of model 2
 Extension boom  Roller bearings
 Safety bypass relief valve  Balancing load at the back.
 Crane has phenolic wheels  Hook
 Horizontal frame  Bolt and nut
The working principle of model -2 is the same as that of model -1 except balancing load at the
back. The lifting load in the crane is must be balance at the back load. If the lifting load is
greater than the balancing load at the back, the crane is not safe.

 Beech Counterweighted Crane is designed without front legs.
 Thus eliminating interference with load lifting or equipment.
 Safety swivel hook is attached directly to extension boom and
 Safety bypass relief valve is standard to prevent dangerous overloading.
 For ease of movement, crane has phenolic wheels with roller bearings.
 But this type of crane is expensive,
 Needs extra load for safety,
 Minimum height
 Limited capacity
 That is it can’t be load greater than the balancing load at the back.
3. MODEL-3
Figure 3:4.Manual mobile material handling machine
 Boom  Handle
 Hook  Rope
 Wheel  Pulley
 Base frame  Coiler
 Bolt and nut  Gear box


The working principle is when the operator turns clock wise the Handle at back the rope coiled at
the coiler by the help of gear box. So the Rope reduce its length. The Rope lift the load at the front
by using hook in the help of pulley to multiply force to lift the load. To move the crane from place
to place apply pushing force at back. When the crane reaches at desired place and to lower the
load, rotate the handle anti clockwise.
 It is suitable for Indoor and Outdoor services.
 It is the basic requirement in all the motor garages.
 Machine shop for loading and unloading of the engines Materials from the vehicles.
 But it is tedious during operation.
 It requires strong man.
 It is costly due to rope, pulley gear mechanism.
 The teeth wear.
4. MODEL-4
Figure 3:5.Mobile jib crane
 Extension boom  Cable or remove control
 Wheel  Bolt and nut
 Motor

 Hydraulic creation, manual or  Powered treble trolley

powered  Optional powered rotation
 Two speed electric hoist
When the Motor turn on, hydraulic creation powered at the back to retract in order to lower
Powered treble trolley to pick the load at lower position. Powered treble trolley to pick the load.
Then the hydraulic creation powered to extract in order to lift the load and rotate to place the
load at desired position and the load place when the hydraulic creation powered to extract again.
 It is practical manual handling aid,
 Approved by the Technical Control Board (TÜV) in Germany,
 A top quality piece of lifting equipment as totally unique in its design.
 The crane features easy handling and increased work place safety through high quality
products standard.
 It is a collapsible unit which enables easier transportation through low headroom areas
such as doorways and it rotate 360 degree to lift load.
 This design uses generator or motor for its loading system due to this it may have
unwanted noise and high output cost.
 Also it uses for huge loads which makes it to increase its manufacturer cost.

5. MODEL-5
Figure 3:6.Rotating floor crane machine
 Boom  Hydraulic jack
 Base frame  Bolt and nut
 Hook  Wheel
 Operating instructions of model 5
1. Insert the jack lever into the hole of the lever socket.
2. Make sure the saddle is correctly positioned. To prevent damage to the jack, do not
move the jack while the lever is intact in the socket.
3. To raise load, use hand to hold the part of the lever, and use the hand to move up and
down at the rear end of the lever.
4. To lower load, use one hand to hold the front part of the handle and use the other to
turn at the rear end of the lever slowly.
Hydraulic jack works on the principle of ―Pascal‘s law‖.

When the lever is operated, the plunger reciprocates then the oil from the reservoir is sucked into
the plunger cylinder during upward stroke of the plunger through the suction valve. The oil in the

plunger cylinder is delivered into the ram cylinder during the downward stroke of the plunger
through the delivery valve.
This pressurized oil lifts the load up, which is placed on top plate of the ram. After the work is
completed the pressure in the ram cylinder is released by unscrewing the lowering screw thus the
pressure releases and the ram is lowered, then the oil is rushed into the reservoir. It consists of
plunger cylinder on one side and ram cylinder on the other side. These two cylinders are mounted
on base which is made of mild steel. Plunger cylinder consists of plunger which is used to build
up the pressure by operating the lever. Plunger cylinder consists of two non-return valves i.e. one
for suction and other for delivery. Ram cylinder consists of ram which lifts the load. The ram
cylinder connected to delivery valve of plunger cylinder. It is also consists of lowering screw this
is nothing but a hand operated valve used for releasing the pressure in the ram cylinder for get
down the load.
Figure 3:7.Working principle of hydraulic jack
 On Design of Rotating Floor Crane, Working with Applied Hydrotech.
 This crane needs gear box to transmit motion and power from hand to the rotating
column.
 The structure is exposed to stress and fracture.

6. MODEL-6
Figure 3:8.Cantilever beam of jib crane.
 Boom
 Trolley
 Mast
 Gusset
 Trapezoidal web
The applied forces diagram details the relative position and direction of the forces that this jib
crane applies to the supporting structure when a load is picked up.
 Free Standing
When a load is applied to the crane, the front of the head assembly, the front of the base plate,
and the front gussets are in compression (exerting thrust); the back boom plate, the back of the
head and the back of the gussets are placed in tension (pulling). These forces put a moment on
the foundation and exert significant thrust & pull on the crane which must be of sufficient size to
resist the forces.

 Wall/Column Mounted
When a load is applied, the top wall bracket applies a downward and outward force on its
support. This places the support in tension (pulling). The bottom wall bracket applies a
downward and inward force on its support, placing it in compression (exerting thrust). These
Thrust & Pull forces are significantly higher than the capacity of the crane! Be sure to have a
qualified structural engineer verify the adequacy of the supporting structure.
 FEA and experimental study are carried out for regular and proposed beam to calculate
and validate results.
 Uniformly distributed load on cantilever.
 Thickness of web and flange is constant for all specimens with length 2.4m and tested for
500kg load lifting capacity.
 Provides a versatile and economical solution where 360º rotation is desired.
 Often used when the thrust and pull exerted by other crane types is too great.
 The key to Gorbel’s superior Mast Type jib lies in the quality bearing design.
 Crane is easy to level during installation.
 The beam fails due to Lateral Torsional buckling.
 Sectional cross section of cantilever beam influences the resistance to lateral torsional
buckling and bending.
7. MODEL 7
Figure 3:9.Side view of general assembly

 Base  Pump Lever
 Mast  Lift cylinder
 Metal Roller  Hook
 Pump  Boom
 Handle  Load locking device
A mobile floor crane is equipment with portable features which makes it admirable and
recommended for both indoor (workshop/ warehouse) and outdoor purposes, for the sole aim of
lifting and moving heavy materials from one place to another. Some of these features found in
them include; adjustable boom, hydraulic height and balance due to rest base design. These
adjustable features are to accommodate various heights and sizes of materials to be lifted. This
project gains its uniqueness with the design of a dead stop incorporated in its mast, to tackle the
issue of failure due to static load. There are also provisions for counter weights at the rear base for
cases where the boom is extended beyond the front base wheel to balance the weight of the material
to be lifted.
 Transportation of heavy machine parts within and outside the workshop.
 It can also be used to load and unload machine parts on trucks.
 For the sole aim of lifting and moving heavy materials from one place to another.
 Dead stop incorporated in its mast to tackle the issue of failure due to static load.
 These adjustable features are to accommodate various heights and sizes of materials
to be lifted.
 For counter weights at the rear base for cases where the boom is extended beyond the
front base wheel to balance the weight of the material to be lifted.
 For permanent joints, the arc welding process was employed.
 High fracture of teeth and lock device

3.2.1. Design Matrix

Design matrix a method used to compare the different models according their material property,
function, operation, availability, cost required etc. and is used to choose the most acceptable,
excellent, preferable, model for design purpose.
Table 3:1.Comparison criteria for each model
Function Model designation

No requirement
Model Model Model Model Model Model Model

1 2 3 4 5 6 7
Physical
functionality
1
Complexity 4 4 3 5 5 3 4
Weight 5 4 2 5 5 3 3
Operability 5 5 3 2 4 2 3
Mechanical
functionality
Wear failure 4 3 3 2 4 2 2
reduction
Fatigue and creep
failure reduction 4 3 2 3 4 3 3
2
Deflection and jerk 3 3 2 2 4 2 2
reduction
Corrosion failure 4 4 3 3 4 3 2
reduction
Reliability 4 4 2 2 4 3 3
Durability 4 4 2 2 5 3 3
Stability 3 5 3 3 4 4 3

Materials
functionality
Strength 4 3 3 3 4 4 4
Availability 4 4 4 3 4 4 3
3 Affordability 4 3 3 2 4 4 3
Manufacturability 4 4 4 3 4 4 3
Maintenance 4 3 4 2 4 4 3
Safety 5 4 3 5 5 4 4
Cost required 5 4 4 2 4 3 3
Total +ve weight 70 62 50 49 72 55 51
for each of Model
% weight= Total 82.35 72.94 58.82 57.64 84.70 64.70 60

+ve weight for each
of Model / Total
weight
i. Safety: Considerations must be carried out through the entire life cycle of the
machine includes Hazards which occurs during
 The process of making the product,
 The expected use of the product,
 Foreseeable misuse & abuse of the product
 Since each design is different, the designer needs to give full consideration to the safety aspect
of the product even if it is the modification of an existing product.
ii. Complicity of mechanisms: the design should not be complex in parts &
operation mechanism; also it can be operated by unskilled person
iii. Manufacturability: the condition that any damaged part of the machine can be
replaced easily with the appropriate spare part when failure is occurred.
iv. Maintainability: the condition that any damaged part of the machine can be
replaced easily with the appropriate spare part when failure is occurred.

v. Cost: Are the basic criteria in designing a machine, low total cost must be the first
target for manufacturing process
 Description:
2. Poor, small, few, low difficult
3. Acceptable, average
4. Great, high, large, possible
5. Excellent, very high
3.2.2. Summary of Literature Review

Our project is mainly focused on modelling and design analysis of manual hydraulic hand lift jib
crane in garages and micro and small enterprises in Ethiopia. This crane is suitable for loading and
unloading heavy material in workshops. From the above required criteria table 3-1 the model are
listed in its % weight for each of Model are 1st (84.70 %) MODEL 5, 2nd (82.35% total) Model 1,
3rd (72.94% total) Model 2. The structure of our design is effective in distribution of load and
minimizes stress comparing with the above table 3-1 (model 5 is the best one). So by taking model
5 we modify to decrease stress of the machine by adding some components, increase balancing
during lifting or carrying loaded object by tilting horizontal frame 45° to the connecting frame and
inclined the back hoist body. This jib crane has four rolling wheels so it can move simply
comparing with beech Counterweighted Crane and it has the capacity to load up to 3 tons,
maximum height 2500mm and minimum height up to 600mm.our design have good capacity to
load and lift materials rather than the above designs. And our design can be manufactured easily
in our country by our product.
3.3. Selection of Materials for Engineering Purposes

 The selection of a proper material, for engineering purposes, is one of the most difficult
problem for the designer. The best material is one which serve the desired objective at the
minimum cost.
 The following factors should be considered while selecting the material:
 Availability of the materials,
 Suitability of the materials for the working conditions in service, and

 The cost of the materials
3.4. Design Part and Stress Analysis

In order to achieve the project, material handling mechanisms were considered. In this condition,
needed to consider:
 Selection of hydraulic bottle jack  Design of back hoist support
 Design of horizontal boom  Design of connecting frame
 Design of back hoist body  Selection of hook
 Design of base body  Design of bolt and nut
 Design of horizontal frame  Selection of wheel
3.5. Draw Part and Assembly Drawing by using Solid Work Software and
Check the Deformation by using ANSYS Software.
 The parts are draw according to the correct dimension get from design analysis of part.
3.6. Result and Discussion

When we compare our design to the existing manually hydraulic hand lift jib crane the stress and
fracture of component is reduced and the stability of the machine is increase by aligned of
horizontal frame by 45 degree. The carrying capacity and lifting height of the machine is increasing
by adding some component.
3.7. Cost Analysis of our Design

A system which systematically recodes all the expenditure to determine the cost of manufactured
products. Generally good, easily, available material selection of horizontal boom, back hoist
support, connecting frame, horizontal fame, base body, nuts and bolts are compatible each other
to resist the direct stress, bending moment and shear stress that occurred during assemble and
disassemble of manually hydraulic hand lift jib crane and to reduce the total cost of the design.
3.8. Recommendation and Conclusion

Because of this machine becomes manual, simple to lift up loads by pumping and it doesn’t ask
qualification of employees, those garages and small and micro enterprises should be use it to
accelerate and to make easily the work activity.

CHAPTER FOUR
4. DESIGN ANALYSIS
4.1. Data Gathering
4.1.1. Interview
In order to strengthen the design, we have added this method. So some employees that are
concern to our project are involved in responding the interview. Totally we interview about some
garages and small and micro enterprise employees. After taking the interviews the customer
statement were understand and analyzed.
Figure 4.1:1.interviewing from different company

4.1.2. Questionnaires
To achieve the purpose of the project about 7 questionnaires are distributed to garages and small
and micro enterprise. Then after the response were tabulated and analyzed. The distributed
questionnaires shows that all most all have lifting machine.
4.1.3. Observation
In order to check and to be sure our project this method is very important. During this observation,
we have observed in person in the place what kinds of machines are present and how they have
used the machines.
Figure 4.1:2.observation of manually hydraulic hand lift fixed jib crane from Jovani garage

Figure 4.1:3.observation of baranco from Jovani garages
Table 4.1:1.Interpretation of interview and distributed questionnaires
Question Customer statement
 We used some times fixed cranes

 Typical uses of lifting  We used cricks
machine  We used forklifts
 We used overhead crane to lift heavy loads
 We lift a load from 2000-3000kg

 Load lifting  We lift a load of about 1000-2000kg
limitation
 Height lifting  We lift a height from 600- 2500mm
limitation
 Accidence on employees when they carry
 Effects through no  It takes huge manpower to carry when it is heavy load
use of lift machine  Lose off safety of the material when the employees
carry the object
 Kind of lift machine  We need to have Mobil hydraulic lift, best than others
needed to have. such as mechanical lifts, fixed cranes...etc.

 Need to have mobile  We need to have this lift in our work shop
hydraulic jib crane.
 We prevent accidence of the employees (keep safety
 Solving problems of the employees)
through using  We decrease the number of manpower during carrying
hydraulic jib crane heavy loads
lift machine  High safety of the material.
4.2. Selection of Hydraulic Bottle Jack

The cylinder capacity for three ton, the stroke rang can be from 3 up to 20 Inch and the type is
aluminum and steel jacks with a model of series JHA/JH EBJL-3GC. Because of the following
advantage are included in the industrial bottle jacks we select it.
 Lower handle effort, reduces operator fatigue
 Fully service cable
 Cast beam and cast pump linkage
 Safety relief valve to prevent over load
 Pumping handle included on all models
 Automatic by pass port to prevent over extension
Figure 4.1.3d view of hydraulic bottle jack

4.2.1. Oil Type

The hydraulic crane is based on a simple concept-the transmission of forces from point to point
through a fluid. Most hydraulic machines use some sort of incompressible fluid, a fluid that is at
its maximum density. Oil is the most commonly fluid for hydraulic machines, including hydraulic
cranes. In a simple hydraulic system, when a piston pushes down on the oil, the oil transmits all of
the original force to another piston, which is driven up. Therefore the oil used for this machine is
hydraulic oil with its viscosity of 22 up to 32.
4.3. Design Specification

 Maximum height=2500mm
 Minimum height =600mm
 Maximum mass=3 ton=3000Kg
 Gravity= g = 9.81m⁄s 2
 Load = mass ∗ g = 3000kg ∗ 9.81 m⁄s 2 = 29430N = 𝟐𝟗. 𝟒𝟑𝟎𝐤𝐍
4.3.1. Geometrical Analysis of the Machine
Figure 4.1:4.3d view of the machine

Figure 4.1:5.Front view of our machine
 The variables are:

 Lb=L1+L2, boom length
 L=L3+L4, back (hoist) body length
 Lm=length of the cylinder at horizontal (normal) position
 Le=extracted cylinder length
 Lr=retracted cylinder length
 θ1=the angle of the boom when extracted from the normal position
 θ2=the angle of the boom when retracted from the normal position
 θ3=the angle between the cylinder and the back hoist body
 θ4=the angle between the back hoist body and horizontal frame
 Therefore from the above geometrical we can assume that Lm is perpendicular to Lb when it
is at normal position. From the above we can draw the following geometrics.
4.3.2. Parameters of the Cylinder from Standard Table

 For three ton read from the appendix table 2.A.
 Maximum height (Le ) =1176.274 mm
 Minimum height (Lr ) =668.274 mm
 Bore diameter =65mm
 Assume

 θ1 = 65°
 θ2 = 50°
 Lb = 1250 mm
Figure 4.1:6.when the cylinder is retracted and extracted triangle
 From the above figure 4.1:3 we can calculate L2 by using cosine law
2
L2 2 L2 2 L2 L2
(Le − Lr ) = + −2 cos(θ1 + θ2 )
cos θ1 cos θ2
2 2 cos θ1 ∗ cos θ2
2
L2 2 L2 2 L2 L2
(1176.274 − 668.274) = 2
+ 2
−2 cos(65 + 50)
cos 65 cos 50 cos 65 ∗ cos 50
(508)2 = 5.6L2 2 + 2.42L2 2 + 3.11L2 2 = 11.13L2 2
 L2 = 𝟏𝟓𝟐. 𝟐𝟕 𝐦𝐦
Figure 4.1:7.When the cylinder is retracted

 From the above triangle figure 4.1:4 we will get

θ4 − θ2 + γ + θ3 = 180°, but θ3 = 90° − θ4
θ4 − θ2 + γ + (90° − θ4) = 180°
γ − θ2 + 90 − 180° = 0, γ = 90° + θ2, but θ2 = 50°
 γ = 90° + θ2 = 90° + 50° = 𝟏𝟒𝟎°
 Also from figure 4.1:4 using cosine law we can calculate L3
L3 2 = Lr 2 + L2 2 − 2 ∗ Lr ∗ L2 ∗ cos γ
L3 2 = (668.274)2 + (152.27)2 − 2(668.274)(152.27)cos(140°)
 L3 = 𝟕𝟗𝟏𝐦𝐦
Figure 4.1:8.When the cylinder is at normal position
 From the above triangle figure 4.1:5 we will get

θ4 + 90° + θ3 = 180°
θ3 = 180° − 90° − θ4 = 90° − θ4
L 152.27
 cosθ4 = L2 , 𝛉𝟒 = Cos −1 ( ) = 𝟕𝟖. 𝟗°
3 791
 𝛉𝟑 = 90 − θ4 = 90 − 78.9° = 𝟏𝟏. 𝟏°

Figure 4.1:9.When the cylinder is extracted
 From the above triangle figure 4.1:6 we will get X by using sine law
X
sin θ1 = L , X=Lb ∗ sin θ1 = 1250 ∗ sin 65°
b
 X=1132.884 mm
Figure 4.1:10.Triangle of back hoist body with base body (∆ACO)
 To find the value of h,L1,L4 we use the above figure 4.1:7

 To get, L1
 L1 = Lb − L2 = 1250mm − 152.27mm = 1097.73mm
 To get the value of the height of the column, h
 h = Lb − X = 2500mm − 1132.884mm = 1367.1mm
h
 Then, sin θ4 = L
h 1367.1mm
 L = sin θ = = 1393.16mm
4 sin 78.9°

 Now, L = L3 + L4
 L4 = L − L3 = 1393.16mm − 791mm = 602.16mm
From the above figure 4.1:2 we can calculate Lh and Xh
Figure 4.1:11.triangle of back hoist body with horizontal frame and back hoist support (∆Aho)
 From the above figure 4.1:8 use sine and cosine law
Lh Xh
 Then, sin θ4 = 2 , cos θ4 = 2
( ∗L3 +L4 ) ( ∗L3 +L4 )
3 3
2 2
 Lh = (3 ∗ L3 + L4 ) ∗ sin θ4 = (3 ∗ 791mm + 602.16mm) ∗ sin 78.9°
 Lh = 1108.364mm
2 2
 Xh = (3 ∗ L3 + L4 ) ∗ cos θ4 = (3 ∗ 791mm + 602.16mm) ∗ cos 78.9°
 Xh = 217.452mm
 To find the pressure of the piston we use moment at point c
Figure 4.1:12.FBD of boom at normal position

 Take moment at point c and counter clockwise positive from the above figure 4.1:9
 ∑M@C =0
 FP*L2-W*(L2+L1) =0
W∗(L2+L1)
 FP = L2
Where, W=mass*acceleration due to gravity

 W = 3000Kg ∗ 9.8m/s 2 = 𝟐𝟗. 𝟒𝟑𝟎𝐤𝐍
29.430KN∗1250mm
 Fp = 152.27mm
 Fp = 𝟐𝟒𝟏. 𝟓𝟗𝟒𝐤𝐍
 Therefore the pressure of the piston will become,
πD2
 Fp = P ∗ Ap , Ap = 4
 Where Ap area of the piston, D=bore diameter =65mm, Fp is force acting on the piston and P
is working pressure of the piston.
Fp 241.594kN
 P=A = π(65mm)2
p
4
 P = 72.806MPa
4.4. Design of Components of Machines

4.4.1. Design of Horizontal Boom
4.4.1.1. Material Selection for Horizontal Boom
The material selection for horizontal boom is low carbon (mild steel) with
mechanical and physical property as follows:
GN
 Young’s modulus of the elasticity (E) =207m2
MN
 Shear modules (G) =80 m2
MN
 Tensile strength (σt) = 480 m2
MN
 Yield strength (σy) = 280 m2
Kg
 Density (ρ) = 7800 m3
 The selected hollow section is square steel.

Figure 4.1:13. 3d views of horizontal boom
4.4.1.2. Horizontal Boom Subjected to Bending Moment

 Parameters that solved from the previous are as shown below:
Figure 4.1:14.FBD of boom when the cylinder at extracted position
 From the above we get

 L1 = 1097.73mm
 L2 = 152.27mm
 Lb = 1250mm
 W=29.430KN
 Fp =241.594kN

First find reaction force

 Force along y-axis from the above figure 4.1:11
 +↑ Σfy = 0
 −fyc − W + Fp ∗ sinβ2 = 0 but , β2 = 90 − θ1 = 90 − 65 = 𝟐𝟓°
 fyc = Fp ∗ sinβ2 − W = 241.594kN ∗ sin25° − 29.430kN
 fyc = 𝟕𝟐. 𝟔𝟕𝟐𝐤𝐍
 Force along x-axis from the above figure 4.1-11
 → +Σfx = 0,
 −fxc + Fp ∗ cosβ2 = 0
 fxc = Fp ∗ cosβ2 = 241.594 ∗ cos25°
 fxc = 𝟐𝟏𝟖. 𝟗𝟓𝟗𝐤𝐍
 Now find Mc, take anti clockwise bending moment at point c are positive
 ∑ M@c = 0, Mc + Fp ∗ sin β2 ∗ L2 − W ∗ Lb = 0
Mc = W ∗ Lb − Fp ∗ sin β2 ∗ L2 = 29.43kN ∗ 1250mm − 241.594kN ∗ sin 25° ∗ 152.27𝑚𝑚
 Mc = 𝟐𝟏𝟐𝟒𝟎. 𝟒𝟐𝟑𝐤𝐍
Bending moment and shear force
 Bending moment and shear force at section x1-x1
Where 0 ≤ x1 ≤ L2 = 152.27mm
To find bending moment at each point take bending moment at point x1 anti clockwise is zero
 ∑ M@x = 0, Mx + Mc + fy ∗ x1 = 0
Mx = −fy ∗ x1 − 𝑀𝑐
 𝐌𝐜@(𝐱𝟏 = 𝟎) = −72.672kN ∗ 0mm − 21240.423kN = −𝟐𝟏𝟐𝟒𝟎. 𝟒𝟐𝟑𝐤𝐍𝐦𝐦 =
𝟐𝟏𝟐𝟒𝟎. 𝟒𝟐𝟑𝐤𝐍𝐦𝐦(𝐜𝐥𝐨𝐜𝐤𝐰𝐢𝐞)

 𝐌𝐝@(𝐱𝟏 = 𝟏𝟓𝟐. 𝟐𝟕𝐦𝐦) = −72.672kN ∗ 152.27mm − 21240.423kNmm =

−𝟑𝟐, 𝟑𝟎𝟔. 𝟏𝟖𝟖𝐤𝐍𝐦𝐦 = 𝟑𝟐, 𝟑𝟎𝟔. 𝟏𝟖𝟖𝐤𝐍𝐦𝐦(𝐜𝐥𝐨𝐜𝐤𝐰𝐢𝐬𝐞)
To find shear force at each point take sum of force along y-axis is zero
 +↑ Σfy = 0, Vx − fy = 0
Vx = fy = 72.672kN
 Vc@(x1 = 0) = Vd@(x1 = 0) = fy = 𝟕𝟐. 𝟔𝟕𝟐𝐤𝐍
 Bending moment and shear force at section x2-x2
Where L2 ≤ x2 ≤ Lb
To find bending moment at each point take bending moment at point x2 anti clockwise is zero
 ∑ M@x2 = 0, Mx + fy ∗ x2 − Fp ∗ sin β2 ∗ (x2 − L2) + Mc = 0
 Mx = Fp ∗ sin β2 ∗ (x2 − L2) − fy ∗ x2 − Mc
 𝐌𝐝@(𝐱𝟐 = 𝐋𝟐) = 241.594kN ∗ sin 25° ∗ (L2 − L2) − fy ∗ L2 − Mc
 𝐌𝐝@(𝐱𝟐 = 𝟏𝟓𝟐. 𝟐𝟕𝐦𝐦) = −72.672kN ∗ 152.27mm − Mc = −11065.765kNmm −
21240.423kNmm = −32,306.188kNmm = 𝟑𝟐, 𝟑𝟎𝟔. 𝟏𝟖𝟖𝐤𝐍𝐦𝐦(𝐜𝐥𝐨𝐜𝐤𝐰𝐢𝐬𝐞)
 𝐌𝐞@(𝐱𝟐 = 𝐋𝐛) = Fp ∗ sin β2 ∗ (Lb − L2) − fy ∗ Lb − Mc
 𝐌𝐞@(𝐱𝟐 = 𝐋𝐛) = 241.594kN ∗ sin 25° ∗ (1250mm − 152.27mm) − 72.672kN ∗
1250mm − 21240.423 = 𝟎. 𝟎𝟒𝟓𝟑𝐤𝐍𝐦𝐦
 +↑ Σfy = 0, Vx − fy + Fp ∗ sin β2 = 0
Vx = fy − Fp ∗ sin β2 = 72.672kN − 241.594 ∗ sin 25° =
−29.43kN
 Vd@(x2 = L2) = Ve@(x2 = Lb) = −𝟐𝟗. 𝟒𝟑𝐤𝐍
 Now maximum bending moment and shear force get at point

 𝐌𝐦𝐚𝐱@𝐝 = 𝟑𝟐𝟑𝟎𝟔. 𝟏𝟖𝟖𝐤𝐍𝐦𝐦

 𝐕𝐦𝐚𝐱@𝐜 = 𝟕𝟐. 𝟔𝟕𝟐𝐤𝐍
𝐌∗𝐲 b b4 −h4
 Hence, 𝛔𝐛 = where, σb =bending stress, y = 2 and I =
𝐈 12
σy MN
 σb = σall = S.F , let S.F=1.5 and σy for mild steel is 280 m2
280MN⁄ 2 MN
 σb = m
= 186.667 m2 = 186.667 N⁄mm2
1.5
b
M∗
 Therefore, σb = 2
b4 −h4
but, M = 32306.188kNmm and b=h+2*t, h=b-2*t
12
b
 Let, b=20*t, t= and h=0.9*b
20
b
32306.188kNmm∗
 186.667 N⁄mm2 = b4 −(0.9∗b)4
2
12
193837.128kNmm∗b
 186.667 N⁄mm2 = 0.3439∗b4
 186.667 N⁄mm2 ∗ b3 = 563,643,873.2Nmm
 b3 = 3,019,515.357mm3
 b = 𝟏𝟒𝟒. 𝟓𝟑𝟕𝐦𝐦
b 144.537mm
 t = 20 = = 𝟕. 𝟐𝟐𝟕𝐦𝐦
20
 But this value of “b” and “t” is not required in standard table, so we take b and t from
standard table by using the value of b ≥ 144.537mm and t ≥ 7.227mm.
 b=203mm,
 t=9.5mm,
 h=b-2t=203mm-2*9.5mm=184mm
 Therefore, checking for the safety:
b 203mm
M∗ 32306.188kNmm∗
 σb = 2
= 2
= 𝟕𝟏. 𝟐𝟗 𝐍⁄
b4 −h4 (203mm)4 −(184mm)4 𝐦𝐦𝟐
12 12
 Now find the new factor of safety (F.s new)

σy 280Mpa
 F. s new = σ = 71.29Mpa = 𝟑. 𝟗𝟐𝟖 > F. s old = 𝟏. 𝟓, so the design of horizontal boom
b
is safe due to bending load when the hydraulic cylinder at extracted position.

4.4.1.3. Horizontal Boom Subjected to Direct Stress

 Direct stress is given by
fxc=Fp∗cos β2
σd = A
Where
 fxc=218.959kN
 A= area of the cross section of the material=b2 − h2
218.959kN
 𝛔𝐝 = (203mm)2 −(184mm)2 = 29.778 𝐍⁄
𝐦𝐦𝟐
 The horizontal boom subjected to direct and bending stress
 𝛔𝒕 = σd + σb = 29.778Mpa + 71.29Mpa = 𝟏𝟎𝟏. 𝟎𝟔𝟖𝐌𝐩𝐚
4.4.1.4. Horizontal Boom Subjected to Shear Stress
 The shear stress on the square hollow section on the boom when cylinder is extracted
will become:
 Shear stress on the square hollow section on the boom is
Vmax
 τ= ,
A
Where
 Vmax = 72.672kN
 A=area of the cross section of the material=b2 − h2
F Fyc 72.672kN 72.672kN

 τ=A= = = 2032 −1842 = 𝟗. 𝟖𝟖𝟑𝐌𝐩𝐚
A b2 −h2
According the principal stress the following equation can be solving the principal stress.
1 1
 σp = 2 (σ𝑡 ± √σ𝑡 2 + 4 ∗ τ2 ) = 2 (101.068Mpa ±
√(101.068Mpa)2 + 4 ∗ (9.883Mpa)2 )
 𝛔𝟏 = 𝟏𝟎𝟐. 𝟎𝟐𝟔𝐌𝐩𝐚 And 𝛔𝟐 = −𝟎. 𝟗𝟓𝟖𝐌𝐩𝐚, 𝛔𝟑 = 𝟎
 Therefore the maximum shear stress theory is:
1
 τmax = 2 (σ1 − σ2) = 1⁄2 (102.026Mpa − (−0.958Mpa))
 τmax = 𝟓𝟏. 𝟒𝟗𝟐𝐌𝐩𝐚

σy 280Mpa
 𝐅. 𝐬 𝐧𝐞𝐰 = 2∗τ = 2∗51.492Mpa = 2.719 > 1.5, it is 𝐬𝐚𝐟𝐞!
max

 And to find the safety factor use of the maximum distortion energy theory
σy
 σ12 + σ22 − 2 ∗ σ1 ∗ σ2 = ( f.s )2
σy
 (102.026)2 + (−0.958)2 − 2 ∗ 102.026 ∗ −0.958 = ( f.s )2
σy 2
 ( f.s ) = 10,605.704Mpa2
σy
 = 102.984Mpa
F.s
σy 280Mpa
 F. s new = 102.984Mpa = 102.984Mpa = 2.719 > 1.5, it is 𝐬𝐚𝐟𝐞!
∴ 𝐝𝐞𝐬𝐢𝐠𝐧 𝐨𝐟 𝐡𝐨𝐫𝐢𝐳𝐨𝐧𝐭𝐚𝐥 𝐛𝐨𝐨𝐦 𝐢𝐬 𝐬𝐚𝐟𝐞 𝐝𝐮𝐞 𝐭𝐨 𝐛𝐞𝐧𝐝𝐢𝐧𝐠 𝐥𝐨𝐚𝐝, 𝐚𝐱𝐢𝐚𝐥 𝐥𝐨𝐚𝐝 𝐚𝐧𝐝 𝐬𝐡𝐞𝐚𝐫 𝐥𝐨𝐚𝐝.
4.4.2. Design of Back Hoist Body

4.4.2.1. Material Selection for Back Hoist Body
The material selection for back hoist body is low carbon (mild steel) with mechanical
and physical property as follows:
GN
MN
MN
MN
Kg
 Density (ρ) = 7800 m3

Figure 4.1:15.3d views of back hoist body
4.4.2.2. Back Hoist Body Subjected to Bending Moment


Figure 4.1:16.FBD of the hoist body
 From horizontal boom we get the following values

 Fxc=218.959kN
 Fyc=72.672kN
 Fp=241.594kN
 Mc=21240.423kNmm
 From the above figure 4.1:13
 Fy ′ c = Fxc ∗ cos 53.9° + Fyc ∗ sin 53.9° = 218.959kN ∗ cos 53.9° + 72.672kN ∗
sin 53.9°
 Fy ′ c = 187.728kN
 Fx ′ c = Fxc ∗ sin 53.9° − Fyc ∗ cos 53.9° = 218.959kN ∗ sin 53.9° − 72.672kN ∗
cos 53.9°
 Fx ′ c = 134.099kN
 Fy ′ b = Fp ∗ sin θ3 = 241.594kN ∗ sin 11.1° = 46.512kN
 Fx ′ b = Fp ∗ cos θ3 = 241.594kN ∗ cos 11.1° = 237.074kN

First find reaction force and moment

 Force along y-axis from the above free body diagram
 +↑ ΣFy′ = 0
 Fy ′ c − Fy ′ h − Fy ′ b + Fy′a = 0
 Fy ′ h − Fy ′ a = Fy ′ c − Fy ′ b = 187.728kN − 46.512kN
 Fy ′ h − Fy ′ a = 141.216kN
 Fy ′ h = Fy ′ a + 141.216kN………………….[1]
 Force along x-axis from the above figure 4.1-13
 → +ΣFx′ = 0,
 −Fx ′ c + Fx ′ b − Fx′a = 0
 Fx ′ a = Fx ′ b − Fx ′ c = 237.074kN − 134.099kN
 Fx ′ a = 102.975kN
 To find Ma, Fy’a and Fy’h , we use Macaulay's method for statically indeterminate beams
 Bending moment at section x-x is
 Mxx = Mc + Fy ′ c ∗ x + Mh − Fy ′ h(x − 263.667) − Fy′b(x − 791)
 Mxx = Mc + Fy ′ c ∗ x + Mh − Fy ′ h ∗ x + 263.667 ∗ Fy ′ h − Fy ′ b ∗ x + 791 ∗ Fy ′ b
 Mxx = (Mc + Mh + 263.667 ∗ Fy ′ h + 791 ∗ Fy ′ b) + (Fy ′ c − Fy ′ h − Fy ′ b) ∗ x
d2 y
 EI dx2 = Mxx = (Mc + Mh + 263.667 ∗ Fy ′ h + 791 ∗ Fy ′ b) + (Fy ′ c − Fy ′ h − Fy ′ b) ∗ x
 Integrate both sides and then as follow

dy x2
 EI dx = (Mc + Mh + 263.667 ∗ Fy ′ h + 791 ∗ Fy ′ b)x + (Fy ′ c − Fy ′ h − Fy ′ b) + C1
2
x2 x3
 EIy = (Mc + Mh + 263.667 ∗ Fy ′ h + 791 ∗ Fy ′ b) + (Fy ′ c − Fy ′ h − Fy ′ b) +
2 6
C1x + C2

 Now consider the boundary condition

 x=0, y=0 then
02 03
 EI ∗ 0 = (Mc + Mh + 263.667 ∗ Fy ′ h + 791 ∗ Fy ′ b) + (Fy ′ c − Fy ′ h − Fy ′ b) +
2 6
C1 ∗ 0 + C2
 C2 = 0
dy
 x=0, dx = 0 then
02
 EI ∗ 0 = (Mc + Mh + 263.667 ∗ Fy ′ h + 791 ∗ Fy ′ b) ∗ 0 + (Fy ′ c − Fy ′ h − Fy ′ b) +
2
C1
 C1 = 0
 x=1393.16, y=0 then
1393.162
 EI ∗ 0 = (21240.423 + Mh + 263.667 ∗ Fy ′ h + 791 ∗ 46.512) + (187.728 −
2
1393.163
Fy ′ h − 46.512) 6
 970,447.393Mh − 194787877.2Fy ′ h + 1,199,572,376,00 = 0 … … … [2]

dy
 x=1393.16, dx = 0, then
 EI ∗ 0 = (21240.423 + Mh + 263.667 ∗ Fy ′ h + 791 ∗ 46.512) ∗ 1393.16 +

1393.162
(187.728 − Fy ′ h − 46.512)
2
 1393.16Mh − 603117.075Fy ′ h + 217889745.1 = 0 … … … [3]

 Now find Mh and Fy’h by using simultaneous equation,
2
 Multiply equation 2 by 1393.16
2
 (970,447.393Mh − 194787877.2Fy ′ h + 119,957,237,600 = 0) ∗ 1393.16
 1393.16Mh − 279,634.61Fy ′ h + 172,208,845.5 = 0 … … … … … … . [4]

 Now subtract equation 4 and equation 2
 1393.16Mh − 279,634.61Fy ′ h + 172,208,845.5 = 0
 1393.16Mh − 603,117.075Fy ′ h + 217889745.1 = 0
 Then
 323,482.465Fy ′ h − 45,680,899.6 = 0
 323,482.465Fy ′ h = 45,680,899.6

 Fy ′ h = 141.216kN
 From equation 1
 Fy ′ h = Fy ′ a + 141.216kN
 141.216kN = Fy ′ a + 141.216kN
 Fy ′ a = 0kN
 From equation 3
 1393.16Mh − 603,117.075Fy ′ h + 217,889,745.1 = 0
 1393.16Mh = 603,117.075 ∗ 141.216 − 217,889,745.1
 1393.16Mh = −132,719,964.2kNmm
 Mh = −95,265.414kNmm = 95,265.414kNmm(anticlockwise)
 To find Ma Taking clockwise bending moment at point c are positive
 ∑ M@c = 0, Mc + Fy ′ h ∗ 263.667 + Mh + Fy ′ b ∗ 791 − Fy ′ a ∗ 1393.16 − Ma = 0
 Ma = 21240.423 + 141.216 ∗ 263.667 − 95,265.414 + 46.512 ∗ 791 − 0 ∗
1393.16
 Ma = 0.000072kNmm
 Maximum bending moment is occur at point h
 𝐌𝐦𝐚𝐱@𝐡 = 𝟗𝟓𝟐𝟔𝟓. 𝟒𝟏𝟒𝐤𝐍𝐦𝐦
𝐈 12
σy MN
280MN⁄ 2 MN
 σb = m
= 186.667 m2 = 186.667 N⁄mm2
1.5
b
M∗
b4 −h4
but, M = 95,265.414kNmm and b=h+2*t, h=b-2*t
12
b
 Let, b=20*t, t=20 and h=0.9*b
b
95,265.414kNmm∗
 186.667 N⁄mm2 = b4 −(0.9∗b)4
2
12
571,592.484kNmm∗b
 186.667 N⁄mm2 = 0.3439∗b4
 186.667 N⁄mm2 ∗ b3 = 1,662,089,224Nmm
 b3 = 8,904033.512mm3

 b = 𝟐𝟎𝟕. 𝟐𝟔𝟔𝐦𝐦
b 207.266mm
 t = 20 = = 𝟏𝟎. 𝟑𝟔𝟑𝐦𝐦
20
 b=250mm,
 t=12mm,
 h=b-2t=250mm-2*12mm=226mm
b 250mm
M∗ 95265.414kNmm∗
 σb = 2
= 2
= 𝟏𝟏𝟎. 𝟏𝟑𝟒 𝐍⁄
b −h4
4 (250mm) −(226mm)4
4
𝐦𝐦𝟐
12 12

σy 280Mpa
 F. s new = σ = 110.134Mpa = 𝟐. 𝟓𝟒𝟐 > F. s old = 𝟏. 𝟓, so the design of back hoist body
b
is safe due to bending load.

4.4.2.3. The Back Hoist Body Subjected to Direct Stress
Fx′a
 σd = A
Where
 Fx ′ a = 102.975𝑘𝑁
102.975kN
 𝛔𝐝 = (250mm)2 −(226mm)2 = 𝟗. 𝟎𝟏𝟒 𝐍⁄
𝐦𝐦𝟐
 The back hoist body subjected to direct and bending stress
o 𝛔𝒄 = σd + σb = 9.014Mpa + 110.134Mpa = 𝟏𝟏𝟗. 𝟏𝟒𝟖𝐌𝐩𝐚
4.4.2.4. Back Hoist Body Subjected to Shear Stress
 The shear stress on the square hollow section on back hoist body when the boom is
extracted will become:
 Shear stress on the square hollow section on back hoist body is
Vmax
 τ= ,
A
Where

 Vmax = Fy ′ c = 187.728kN
F Fy′c 187.728kN 187.728kN

 τ=A= = = 2502 −2262 = 𝟏𝟔. 𝟒𝟑𝟑𝐌𝐩𝐚
A b2 −h2
1 1
 σp = 2 (σ𝑐 ± √σ𝑐 2 + 4 ∗ τ2 ) = 2 (119.148Mpa ±
√(119.148Mpa)2 + 4 ∗ (9.014Mpa)2 )
 𝛔𝟏 = 𝟏𝟏𝟗. 𝟖𝟐𝟔𝐌𝐩𝐚 And 𝛔𝟐 = −𝟎. 𝟔𝟕𝟖𝐌𝐩𝐚, 𝛔𝟑 = 𝟎𝐌𝐩𝐚
1
 τmax = 2 (σ1 − σ2) = 1⁄2 (119.826Mpa + 0.678Mpa)
 τmax = 𝟔𝟎. 𝟐𝟓𝟐𝐌𝐩𝐚

σy 280Mpa
max
σy
 σ12 + σ22 − 2 ∗ σ1 ∗ σ2 = ( f.s )2
σy
 (119.826)2 + (−0.678)2 − 2 ∗ 119.826 ∗ −0.678 = ( f.s )2
σy 2
 ( f.s ) = 14,521.214Mpa2
σy
 = 120.504Mpa
F.s
σy 280Mpa
∴ 𝐝𝐞𝐬𝐢𝐠𝐧 𝐨𝐟 𝐛𝐚𝐜𝐤 𝐡𝐨𝐢𝐬𝐭 𝐛𝐨𝐝𝐲 𝐢𝐬 𝐬𝐚𝐟𝐞 𝐝𝐮𝐞 𝐭𝐨 𝐛𝐞𝐧𝐝𝐢𝐧𝐠 𝐥𝐨𝐚𝐝, 𝐚𝐱𝐢𝐚𝐥 𝐥𝐨𝐚𝐝 𝐚𝐧𝐝 𝐬𝐡𝐞𝐚𝐫 𝐥𝐨𝐚𝐝.
4.4.2.5. Back Hoist Body Subjected to Buckling and Crushing Load

 Therefore we can find the force acting on the back hoist body axially.
 axial load acting on the back hoist body
 F𝑎𝑥𝑖𝑎𝑙 = Fx ′ b + Fx ′ c = 237.074kN + 134.099kN
 F𝑎𝑥𝑖𝑎𝑙 = 𝟑𝟕𝟏. 𝟏𝟕𝟑𝐤𝐍
 Hence if the slenderness ratio is less than 80, Euler’s formula for a mild steel column is
not valid.

 Sometimes, the columns whose slenderness ratio is more than 80, are known as long
columns, and those whose slenderness ratio is less than 80 are known as short columns.
It is thus obvious that the Euler’s formula holds good only for long columns.
 Now find slenderness ratio in order to the back hoist body is long or short column.
effective length of the back hoist body 𝑙
 slenderness ratio = the least radius of gyration of the section = 𝑘
Table 4.1:2.Standard table of the relation between equivalent length (l) and actual length (L)
No End condition Relationship
1 Both ends hinged l=L
2 Both ends fixed L

l=2
3 One end fixed and other hinged L

l=
√2
4 One end fixed and other end free l=2L
 Then from the above table 4.1:2 we select that one end fixed and other end hinged
L 1393.16mm
𝑙= and the value of L is 1393.16mm then 𝑙 = = 𝟗𝟖𝟓. 𝟏𝟏𝟑𝐦𝐦
√2 √2
 The least radius of gyration of the square hollow section (k) is given by
 k = 0.289√h2 + b 2 = 0.289√2502 + 2262 = 𝟗𝟕. 𝟑𝟗𝟔𝐦𝐦
 Then
l 985.113mm
 slenderness ratio = k = = 𝟏𝟎. 𝟏𝟏𝟒 < 𝟖𝟎, so the back hoist
97.396mm
body is a short column

 In column ((hoist) design we concede about the Ewers column theory and Rankine’s
columns theory formula.
Note: Euler’s formula gives correct results only for very long columns. Though Rankine’s
formula is applicable for columns, ranging from very long to short ones, yet it does not give
reliable results. So, we use Rankine’s formula because the column is short.
 The column will fall by crushing and the load will be known as crushing load and the
load at which the column tends to have lateral displacement or tender to buckler

called buckling load, critical load or crippling load (Wcr) and the column is said to
be have developed on elastic instability.
Rankine’s column theory
 According to Rankine’s column theory, crippling load (Wcr) as follows:
1 1 1
 = WC + WE
Wcr
Wc∗WE Wc
 Wcr = WE+Wc = Wc
1+
WE
σc∗A σc∗A σc∗A

 Wcr = σC A∗L2
= σC L2
= a L
1+ 2 ∗ 1+ 2 ∗ 2 1+ ∗( )2
cπ ∗E A∗K2 cπ ∗E K 𝑐 K
Where
 Wcr=crippling load by Rankine’s formula
 Wc=ultimate crushing load for column= σc ∗ A
cπ2 ∗E∗A
 WE=crippling load obtain by Ewer’s formula= L
( )2
k
 I=A*K 2 moment inertia

 σc =Crushing yield stress
 A=cross section area of the column= 𝐡𝟐 − 𝐛𝟐
σC
 a=Ranking constant= π2 ∗E
 L=equivalent length of the column

 K=least radius of gyration, 𝐊 = 𝟎. 𝟐𝟖𝟗√𝐡𝟐 + 𝐛 𝟐 (for the square hollow section)
 C=constant, representing the end condition of the column or end fixity coefficient.
 The following value of C as showing in the table below:
Table 4.1:3.Standard value of “c”
NO End condition coefficient
1 Both end hinged 1
2 Both end fixed 4
3 One end fixed and other hinged 2

4 One end fixed and other end free 0.25
 From the above table 4.1:3 the value of C is select 2 because of back hoist body is one
end fixed and other is hinged.
Table 4.1:4.Value of crushing stress (σc) and Rankine’s constant (a)
𝛔𝐜
NO Materials 𝛔𝐜 in M pa a=𝛑𝟐 ∗𝐄
1 Wrought iron 250 1⁄

9600
2 Cast iron 550 1⁄

1600
3 Mild steel 320 1⁄

7500
4 Timber 50 1⁄
750
 using mild steel read from above table 4.1:4,

 a=1/7500
 σC =320Mpa
 crushing load is given by
320N
Wc = σc ∗ A = ∗ ((250mm)2 − (226mm)2 ) = 3,655,680𝑁 = 3,655.680𝐤𝐍
mm2
Wc 3,655.680𝐤𝐍
 F. s new = Fx′a = = 9.849 > 1.5, it is 𝐬𝐚𝐟𝐞!
371.173kN
 crippling load is given by

320N/mm2 ∗ ((250mm)2 − (226mm)2 ) 3,655.680𝑘𝑁
Wcr = =
1 2 1.00682
1+ ∗ (10.114mm)
2 ∗ 7500
Wcr = 𝟑, 𝟔𝟑𝟎. 𝟗𝟏𝟕𝟏𝟒𝟓𝐤𝐍
Wcr 3630.917145
 F. s new = Fx′a = = 9.782 > 1.5, it is 𝐬𝐚𝐟𝐞!
371.173kN
∴ 𝐝𝐞𝐬𝐢𝐠𝐧 𝐨𝐟 𝐛𝐚𝐜𝐤 𝐡𝐨𝐢𝐬𝐭 𝐛𝐨𝐝𝐲 𝐢𝐬 𝐬𝐚𝐟𝐞 𝐝𝐮𝐞 𝐭𝐨 𝐜𝐫𝐢𝐩𝐩𝐥𝐢𝐧𝐠 𝐥𝐨𝐚𝐝 𝐨𝐫 𝐛𝐮𝐜𝐤𝐥𝐢𝐧𝐠 𝐥𝐨𝐚𝐝 𝐚𝐧𝐝 𝐜𝐫𝐮𝐬𝐡𝐢𝐧𝐠 𝐥𝐨𝐚𝐝.

4.4.3. Design of the Horizontal Frame and Base Body

 Using the geometric method from the free body diagram below when the cylinder is at
normal position, the total length of the horizontal frame will become:
Figure 4.1:17.front view of machine
 To find m use cosine law

m
 Therefore, cos θ4= , m = L ∗ cos θ4 , but L = 1393.16mm and θ4 = 78.9°
L
 m = L ∗ cos θ4 = 1393.16 ∗ cos 78.9° = 𝟐𝟔𝟖. 𝟐𝟏𝟒𝐦𝐦

 n = Lb − m = 1250 − 268.214 = 𝟗𝟖𝟏. 𝟕𝟖𝟔𝐦𝐦, which is value from
center to center
 But, to find the lengths of both sides of the horizontal frame from the FBD below is:

Figure 4.1:18.Top view of machine
 Therefore from the above FBD the values of “x” and “y” are
y y
 tan 45° = =
m 268.214mm
 y = 268.214mm ∗ tan 45° = 𝟐𝟔𝟖. 𝟐𝟏𝟒𝐦𝐦

y y 268.214
 sin 45° = x , x = sin 45° = = 𝟑𝟕𝟗. 𝟑𝟏𝟐𝐦𝐦
sin 45°
 Hence, the total length of the base body (Ltb ) is equal to the total length of the connecting
frame(Lc ) will become:
 Ltb = Lc = 400mm + 2 ∗ y = 400 + 2 ∗ 268.214mm = 𝟗𝟑𝟔. 𝟒𝟐𝟖𝐦𝐦
 And also the total length of the horizontal frame(LT ) using equivalent triangle is:
m x
 =L
n+m T
(n+m)∗x
 LT = m
(981.786mm+268.214)∗379.312mm
 LT = = 𝟏𝟕𝟔𝟕. 𝟕𝟔𝟖𝐦𝐦
268.214mm
 Therefore the total length of the horizontal frame is 1767.768mm.

4.4.4. Design of Base Body

4.4.4.1. Material Selection for Base Body
The material selection for base body is low carbon (mild steel) with mechanical and
physical property as follows:
GN
MN
MN
 Tensile strength (σt) = 480
m2
MN
Kg
 Density (ρ) = 7800 m3
Figure 4.1:19.3d view of base body
4.4.4.2. Base Body Subjected to Bending Moment


Figure 4.1:20.FBD of base body

 From horizontal boom we get the following values
 Fx ′ a = 102.975kN
 θ4 = 78.9°
Fx′ a ∗sin θ4∗Ltb
 Mi = = 11,828.094kNmm(anticlockwise)[see from beam design
8
formula page 15]

 Mj = −Mi = −11,828.094kNmm = 11,828.094kNmm(clockwise)
 Force along y-axis from the above figure 4.1:17
 +↑ ΣFy = 0
 Fyi + Fyj − Fx ′ a ∗ sin θ4 = 0
 Fyi + Fyj = Fx ′ a ∗ sin θ4 = 102.975kN ∗ sin 78.9°
 Fyi + Fyj = 101.049kN, because the force is at the center, so Fyi =
Fyj,
 Fyi + Fyi = 2Fyi = 101.049kN
 Fyi = Fyj = 𝟓𝟎. 𝟓𝟐𝟓𝐤𝐍
 Force along x-axis from the above figure 4.1:17
 ← +ΣFx = 0,
 Fxi + Fxj − Fx ′ a ∗ cos θ4 = 0

 Fxi + Fxj = Fx ′ a ∗ cos θ4 = 102.975kN ∗ cos 78.9° = 𝟏𝟗. 𝟖𝟐𝟓𝐤𝐍

because the force is at the center, so Fxi = Fxj
19.825kN
 Fxi = Fxj = = 𝟗. 𝟗𝟏𝟐𝐤𝐍
2
 Bending moment and shear force

 Bending moment and shear force at section x1-x1
Ltb
Where 0 ≤ x1 ≤ = 468.214mm
2
To find bending moment at each point take bending moment at point x1 anti clockwise is
zero
 ∑ M@x = 0, Mx + Mi − Fyi ∗ x1 = 0
Mx = Fyi ∗ x1 − Mi
 𝐌𝐢@(𝐱𝟏 = 𝟎) = 50.525kN ∗ 0mm − 11,828.094kNmm = −𝟏𝟏, 𝟖𝟐𝟖. 𝟎𝟗𝟒𝐤𝐍𝐦𝐦
 𝐌𝐀@(𝐱𝟏 = 𝟒𝟔𝟖. 𝟐𝟏𝟒𝐦𝐦) = 50.525kN ∗ 468.214mm − 11,828.094kNmm =
−𝟏𝟏, 𝟖𝟐𝟖. 𝟎𝟗𝟒𝐤𝐍𝐦𝐦
 +↑ Σfy = 0, Vx + Fyi = 0
Vx = −Fyi = −50.525kN
 Vi@(x1 = 0mm) = VA@(x1 = 468.214mm) = −Fyi = −𝟓𝟎. 𝟓𝟐𝟓𝐤𝐍

Ltb
Where 0 ≤ x2 ≤ = 468.214mm
2
To find bending moment at each point take bending moment at point x2 clockwise is zero
 ∑ M@x2 = 0, Mx + Mj − Fyj ∗ x2 = 0
 Mx = Fyj ∗ x2 − Mj
 𝐌𝐣@(𝐱𝟐 = 𝟎) = 50.525kN ∗ 0mm − 11,828.094kNmm =
−𝟏𝟏, 𝟖𝟐𝟖. 𝟎𝟗𝟒𝐤𝐍𝐦𝐦
 𝐌𝐀@(𝐱𝟐 = 𝟒𝟔𝟖. 𝟐𝟏𝟒𝐦𝐦) = 50.525kN ∗ 468.214mm − 11,828.094kNmm =
−𝟏𝟏, 𝟖𝟐𝟖. 𝟎𝟗𝟒𝐤𝐍𝐦𝐦
 +↑ Σfy = 0, −Vx + Fyj = 0
Vx = Fyj = 50.525kN
 Vj@(x2 = 0mm) = VA@(x2 = 468.214mm) = 𝟓𝟎. 𝟓𝟐𝟓𝐤𝐍
 Now maximum bending moment and shear force
 𝐌𝐦𝐚𝐱 = 𝟏𝟏, 𝟖𝟐𝟖. 𝟎𝟗𝟒𝐤𝐍𝐦𝐦
 𝐕𝐦𝐚𝐱 = 𝟓𝟎. 𝟓𝟐𝟓𝐤𝐍
𝐈 12
σy MN
280MN⁄ 2 MN
 σb = m
= 186.667 m2 = 186.667 N⁄mm2
1.5
b
M∗
b4 −h4
12
b
 Let, b=20*t, t=20 and h=0.9*b

b
11,828.094kNmm∗
 186.667 N⁄mm2 = b4 −(0.9∗b)4
2
12
70968.564kNmm∗b
 186.667 N⁄mm2 = 0.3439∗b4
 186.667 N⁄mm2 ∗ b3 = 206,363,954.6Nmm
 b3 = 1,105,519.211mm3
 b = 𝟏𝟎𝟑. 𝟒𝐦𝐦
b 103.4mm
 t= = = 𝟓. 𝟏𝟕𝐦𝐦
20 20
 b=120mm,
 t=6mm,
 h=b-2t=120mm-2*6mm=108mm
b 120mm
M∗ 11,828.094kNmm∗
 σb = 2
= 2
= 𝟏𝟏𝟗. 𝟒𝟐𝟒 𝐍⁄
b4 −h4 (120mm)4 −(108mm)4 𝐦𝐦𝟐
12 12

σy 280Mpa
 F. s new = σ = 119.424Mpa = 𝟐. 𝟑𝟒𝟓 > F. s old = 𝟏. 𝟓, so the design of base body is safe
b
due to bending load.

4.4.4.3. The Base Body Subjected to Direct Stress
Faxial
 σd = A
Where
Fxi+Fxj Fx′ a∗cos θ4 19.824kN
 Faxial = = = = 9.912kN
2 2 2

9.912kN
 𝛔𝐝 = (120mm)2 −(108mm)2 = 𝟑. 𝟔𝟐𝟑 𝐍⁄
𝐦𝐦𝟐
 The base body subjected to direct and bending stress
o 𝛔𝐜 = σd + σb = 3.623Mpa + 119.424Mpa = 𝟏𝟐𝟑. 𝟎𝟒𝟕𝐌𝐩𝐚

4.4.4.4. Base Body Subjected to Shear Stress

 The shear stress on the square hollow section on base body.
 Shear stress on the square hollow section on the base body is
Vmax
 τ= ,
A
Where
 Vmax = Fyj = 50.525kN
F Fy′A 50.525kN 50.525kN

 τ=A= = = 1202 −1082 = 𝟏𝟖. 𝟒𝟔𝟕𝐌𝐩𝐚
A b2 −h2
1 1
 σp = 2 (σ𝑐 ± √σ𝑐 2 + 4 ∗ τ2 ) = 2 (123.047Mpa ±
√(123.047Mpa)2 + 4 ∗ (18.467Mpa)2 )
 𝛔𝟏 = 𝟏𝟐𝟓. 𝟕𝟓𝟗𝐌𝐩𝐚 And 𝛔𝟐 = −𝟐. 𝟕𝟏𝟐𝐌𝐩𝐚, 𝛔𝟑 = 𝟎𝐌𝐩𝐚
1
 τmax = 2 (σ1 − σ2) = 1⁄2 (125.759Mpa + 2.712Mpa)
 τmax = 𝟔𝟒. 𝟐𝟑𝟓𝐌𝐩𝐚

σy 280Mpa
max
σy
 σ12 + σ22 − 2 ∗ σ1 ∗ σ2 = ( f.s )2
σy
 (125.759)2 + (−2.712)2 − 2 ∗ 125.759 ∗ −2.712 = ( f.s )2
σy 2
 ( ) = 16,504.798Mpa2
f.s
σy
 = 128.471Mpa
F.s
σy 280Mpa
∴ 𝐝𝐞𝐬𝐢𝐠𝐧 𝐨𝐟 𝐛𝐚𝐬𝐞 𝐛𝐨𝐝𝐲 𝐢𝐬 𝐬𝐚𝐟𝐞 𝐝𝐮𝐞 𝐭𝐨 𝐛𝐞𝐧𝐝𝐢𝐧𝐠 𝐥𝐨𝐚𝐝, 𝐚𝐱𝐢𝐚𝐥 𝐥𝐨𝐚𝐝 𝐚𝐧𝐝 𝐬𝐡𝐞𝐚𝐫 𝐥𝐨𝐚𝐝.
4.4.4.5. Base Body Subjected to Buckling and Crushing Load

 Therefore we can find the force acting on the base body axially.

 axial load acting on the base body

 F𝑎𝑥𝑖𝑎𝑙 = Fxi + Fxj = Fx ′ a ∗ sin 𝜃4 = 9.912kN + 9.912kN
 F𝑎𝑥𝑖𝑎𝑙 = 𝟏𝟗. 𝟖𝟐𝟒𝐤𝐍
not valid.
effective length of the back hoist body 𝑙
 slenderness ratio = the least radius of gyration of the section = 𝑘
L
Then from the above table 4.1:2 we select that both end fixed l = 2 and the value of L is
936.428mm
936.428mm then l = = 𝟒𝟔𝟖. 𝟐𝟏𝟒𝐦𝐦
2
 k = 0.289√h2 + b 2 = 0.289√1202 + 1082 = 𝟒𝟔. 𝟔𝟓𝟕𝐦𝐦
 Then
l 468.214mm
 slenderness ratio = k = = 𝟏𝟎. 𝟎𝟑𝟓 < 𝟖𝟎, so the back hoist body is a
46.657mm
short column
1 1 1
 = WC + WE
Wcr
Wc∗WE Wc
1+
WE

= σC L2
= a L
1+ 2 ∗ 1+ 2 ∗ 2 1+ ∗( )2
 From the above table 4.1:3 the value of C is select 4 because of base body is both end
fixed.
 a=1/7500
 σc = 320Mpa


320N
Wc = σc ∗ A = ∗ ((120mm)2 − (108mm)2 ) = 875,520N = 𝟖𝟕𝟓. 𝟓𝟐𝐤𝐍
mm2
 Crushing load (Wc = 𝟖𝟕𝟓. 𝟓𝟐𝐤𝐍) >>> axial load (Faxial = 𝟏𝟗. 𝟖𝟐𝟒𝐤𝐍), it is
safe!
320N/mm2 ∗ ((120mm)2 − (108mm)2 ) 875,520N
Wcr = =
1 1.00336
1+ ∗ (10.035)2
4 ∗ 7500
Wcr = 872.591𝐤𝐍
 Crippling load (Wcr = 𝟖𝟕𝟐. 𝟓𝟗𝟏𝐤𝐍) >>> axial load (Faxial = 𝟏𝟗. 𝟖𝟐𝟒𝐤𝐍), it
is safe!
∴ 𝐝𝐞𝐬𝐢𝐠𝐧 𝐨𝐟 𝐛𝐚𝐬𝐞 𝐛𝐨𝐝𝐲 𝐢𝐬 𝐬𝐚𝐟𝐞 𝐝𝐮𝐞 𝐭𝐨 𝐜𝐫𝐢𝐩𝐩𝐥𝐢𝐧𝐠 𝐥𝐨𝐚𝐝 𝐨𝐫 𝐛𝐮𝐜𝐤𝐥𝐢𝐧𝐠 𝐥𝐨𝐚𝐝 𝐚𝐧𝐝 𝐜𝐫𝐮𝐬𝐡𝐢𝐧𝐠 𝐥𝐨𝐚𝐝
4.4.4.6. Deflection of Base Body

 Maximum deflection is given by when beam fixed at both ends-concentrated load at the
center,
Fx′ a∗sin θ4∗Ltb 3
 ∆max (at the center) = 192∗EI
 Where
b4 −h4 1204 −1084
 I= = = 5,942,592mm4
12 12
 Ltb = 936.428mm
 Fx ′ a ∗ sin θ4 = 102.975kN ∗ sin 78.9° = 101.049kN = 101049N
 E = 207 ∗ 103 N/mm2
103 N
 EI = E ∗ I = 207 ∗ mm2 ∗ 5,942,592mm4 = 1230116544000Nmm2
 Now
101049N ∗ 936.428mm3
∆max (at the center) =
192 ∗ 1230116544000Nmm2
 ∆𝐦𝐚𝐱 = 𝟎. 𝟑𝟓𝟏𝐦𝐦
∴ As compared to the length 936.428mm, the deflection of 0.351mm is very negligible.
Therefore, the design is safe!

4.4.5. Design of Back Hoist Support

4.4.5.1. Material Selection for Back Hoist Support
The material selection for back hoist support is low carbon (mild steel) with
GN
MN
MN
 Tensile strength (σt) = 480
m2
MN
Kg
 Density (ρ) = 7800 m3
Figure 4.1:21.3d view of back hoist support
4.4.5.2. Back Hoist Support Subjected to Bending Moment


Figure 4.1:22.FBD of back hoist support
Figure 4.1:23.Side view of back hoist support
Now find , Leh, θh , Lkk
 From horizontal frame

 m = 268.214mm
 Xh = 217.452mm
 Lh = 1108.364mm
 Lkk = 400 + 2 ∗ (m − Xh) ∗ tan 45° = 400 + 2 ∗ (268.214 − 217.452) ∗ tan 45°
 Lkk = 501.524mm
Lkk 2 501.524 2
 Leh = √( ) + Lh2 = √( ) + (1108.364)2
2 2
 Leh = 1136.377mm

Lh Lh 1108.364
 tan θh = Lkk , θh = tan−1[ Lkk ] = tan−1 [ 501.524 ]
( ) ( ) ( )
2 2 2
 θh = tan−1 [4.41998] = 77.25°

 From back hoist body we get the following values
 Fy′h = 141.216kN
 Mh = 95,265.414kNmm
 +↑ ΣFy = 0
Fy′ h
 −Fyk + ∗ cos θh = 0
2
Fy′ h 141.216kN
 Fyk = ∗ cos θh = ∗ cos 77.25° = 15.583kN
2 2
 Force along x-axis from the above figure 4.1:19

 +→ ΣFx = 0,
Fy′ h
 −Fxk + ∗ sin θh = 0
2
Fy′ h 141.216kN
 Fxk = ∗ sin θh = ∗ sin 77.25° = 68.867kN
2 2
 To find Mk use clockwise moment at point k equal to zero

Mh Fy′ h
 ∑ M@k = 0, − Mk − ∗ cos θh ∗ Leh = 0
2 2
Mh Fy′ h 95,265.414 141.216
 Mk = − ∗ cos θh ∗ Leh = − ∗ 1136.377 ∗
2 2 2 2
cos 77.25°
Mk = 29,924.544kNmm
 Now maximum bending moment and shear force get at point ‘h’
Mh 95,265.414kNmm
 𝐌𝐦𝐚𝐱 == = = 𝟒𝟕, 𝟔𝟑𝟐. 𝟕𝟎𝟕𝐤𝐍𝐦𝐦
2 2
 𝐕𝐦𝐚𝐱 = 𝟏𝟓. 𝟓𝟖𝟑𝐤𝐍

𝐈 12
σy MN
280MN⁄ 2 MN
 σb = m
= 186.667 m2 = 186.667 N⁄mm2
1.5

b
M∗
b4 −h4
12
b
 Let, b=20*t, t=20 and h=0.9*b
b
47,632.707kNmm ∗
 186.667 N⁄mm2 = b4 −(0.9∗b)4
2
12
285,796.242kNmm∗b
 186.667 N⁄mm2 = 0.3439∗b4
 186.667 N⁄mm2 ∗ b3 = 831,044,611.8Nmm
 b3 = 4,452,016.756mm3
 b = 𝟏𝟔𝟒. 𝟓𝟎𝟕𝐦𝐦
b 164.507mm
 t = 20 = = 𝟖. 𝟐𝟐𝟓𝐦𝐦
20
 b=175mm,
 t=9mm,
 h=b-2t=175mm-2*9mm=157mm
b 175mm
M∗ 47,632.707kNmm ∗
 σb = 2
= 2
= 𝟏𝟓𝟏. 𝟒𝟏𝟑 𝐍⁄
b4 −h4 (175mm)4 −(157mm)4 𝐦𝐦𝟐
12 12

σy 280Mpa
 F. s new = σ = 151.413Mpa = 𝟏. 𝟖𝟒𝟗 > F. s old = 𝟏. 𝟓, so the design of back hoist
b
support is safe due to bending load.

4.4.5.3. The Back Hoist Support Subjected to Direct Stress
Faxial
 σd = A
Where
Fy′ h
 Faxial = ∗ sin θh = 68.867kN
2

68.867kN
 𝛔𝐝 = (175mm)2 −(157mm)2 = 𝟏𝟏. 𝟓𝟐𝟒 𝐍⁄
𝐦𝐦𝟐
 The back hoist support subjected to direct and bending stress
o 𝛔𝒄 = σd + σb = 11.524Mpa + 151.413Mpa = 𝟏𝟔𝟐. 𝟗𝟑𝟕𝐌𝐩𝐚
4.4.5.4. The Back Hoist Support Subjected to Shear Stress
 The shear stress on the square hollow section on back hoist support.
 Shear stress on the square hollow section on the back hoist support is
Vmax
 τ= ,
A
Where
Fy′ h
 Vmax = ∗ cos θh = 15.583kN
2
Vmax 15.583kN 15.583kN

 τ= = = 1752 −1572 = 𝟐. 𝟔𝟎𝟖𝐌𝐩𝐚
A b2 −h2
1 1
 σp = 2 (σ𝑐 ± √σ𝑐 2 + 4 ∗ τ2 ) = 2 (162.937Mpa ±
√(162.937Mpa)2 + 4 ∗ (2.608Mpa)2 )
 𝛔𝟏 = 𝟏𝟔𝟐. 𝟗𝟕𝟗𝐌𝐩𝐚 And 𝛔𝟐 = −𝟎. 𝟎𝟒𝟐𝐌𝐩𝐚, 𝛔𝟑 = 𝟎𝐌𝐩𝐚
1
 τmax = 2 (σ1 − σ2) = 1⁄2 (162.979Mpa + 0.042Mpa)
 τmax = 𝟖𝟏. 𝟓𝟏𝐌𝐩𝐚

σy 280Mpa
max
σy
 σ12 + σ22 − 2 ∗ σ1 ∗ σ2 = ( f.s )2
σy
 (162.979)2 + (−0.042)2 − 2 ∗ 162.979 ∗ −0.042 = ( f.s )2
σy 2
 ( f.s ) = 26,575.846Mpa
σy
 = 163.021Mpa
F.s
σy 280Mpa

∴ 𝐝𝐞𝐬𝐢𝐠𝐧 𝐨𝐟 𝐛𝐚𝐜𝐤 𝐡𝐨𝐢𝐬𝐭 𝐬𝐮𝐩𝐩𝐨𝐫𝐭 𝐢𝐬 𝐬𝐚𝐟𝐞 𝐝𝐮𝐞 𝐭𝐨 𝐛𝐞𝐧𝐝𝐢𝐧𝐠 𝐥𝐨𝐚𝐝, 𝐚𝐱𝐢𝐚𝐥 𝐥𝐨𝐚𝐝 𝐚𝐧𝐝 𝐬𝐡𝐞𝐚𝐫 𝐥𝐨𝐚𝐝.
4.4.5.5. Back Hoist Support Subjected To Buckling and Crushing Load

 Therefore we can find the force acting on the back hoist support axially.
 axial load acting on the back hoist support
Fy′ h
 F𝑎𝑥𝑖𝑎𝑙 = ∗ sin θh = 𝟔𝟖. 𝟖𝟔𝟕𝐤𝐍
2
not valid.
effective length of the back hoist body l
 slenderness ratio = the least radius of gyration of the section = k
 Then from the above table 4.1:2 we select that one end fixed and the other free 𝑙 =
2L and the value of L is 1136.377mm then 𝑙 = 2 ∗ 1136.377mm =
𝟐, 𝟐𝟕𝟐. 𝟕𝟓𝟒𝐦𝐦
 k = 0.289√h2 + b 2 = 0.289√1752 + 1572 = 𝟔𝟕. 𝟗𝟒𝟓𝐦𝐦
Then
l 2,272.754mm
slenderness ratio = k = = 𝟑𝟑. 𝟒𝟓 < 𝟖𝟎, so the back hoist support is a short
67.945mm
column
1 1 1
 = WC + WE
Wcr
Wc∗WE Wc
1+
WE

= σC L2
= a L
1+ 2 ∗ 1+ 2 ∗ 2 1+ ∗( )2

 From the above table 4.1:3 the value of C is select 0.25 because of back hoist support is
one end fixed and other is free.
 a=1/7500
 σC =320Mpa
320N
Wc = σc ∗ A = ∗ ((175mm)2 − (157mm)2 ) = 𝟏, 𝟗𝟏𝟐. 𝟑𝟐𝐤𝐍
mm2
 Crushing load (Wc = 𝟏, 𝟗𝟏𝟐. 𝟑𝟐𝐤𝐍) >>> axial load (Faxial = 𝟔𝟖. 𝟖𝟔𝟕𝐤𝐍), it
is safe!
320N/mm2 ∗ ((175mm)2 − (157mm)2 ) 1,912.32kN
Wcr = =
1 2 1.597
1+ ∗ (33.45)
0.25 ∗ 7500
Wcr = 𝟏, 𝟏𝟗𝟕. 𝟔𝟑𝟒𝐤𝐍
 Buckling load (Wcr = 𝟏, 𝟏𝟗𝟕. 𝟔𝟑𝟒𝐤𝐍) >>> axial load (Faxial = 𝟔𝟖. 𝟖𝟔𝟕𝐤𝐍),
it is safe!
∴ 𝐝𝐞𝐬𝐢𝐠𝐧 𝐨𝐟 𝐛𝐚𝐜𝐤 𝐡𝐨𝐢𝐬𝐭 𝐬𝐮𝐩𝐩𝐨𝐫𝐭 𝐢𝐬 𝐬𝐚𝐟𝐞 𝐝𝐮𝐞 𝐭𝐨 𝐜𝐫𝐢𝐩𝐩𝐥𝐢𝐧𝐠 𝐥𝐨𝐚𝐝 𝐨𝐫 𝐛𝐮𝐜𝐤𝐥𝐢𝐧𝐠 𝐥𝐨𝐚𝐝 𝐚𝐧𝐝 𝐜𝐫𝐮𝐬𝐡𝐢𝐧𝐠 𝐥𝐨𝐚𝐝
4.4.6. Design of Horizontal Frame

4.4.6.1. Material Selection for Horizontal Frame
The material selection for horizontal frame is low carbon (mild steel) with mechanical
and physical property as follows:
GN
MN
 Shear modules (G) =80
m2
MN
MN
Kg
 Density (ρ) = 7800 m3

Figure 4.1:24.3d view of horizontal frame
4.4.6.2. Horizontal Frame Subjected to Bending Moment

Bending moment Along x-y plane
 And then the free body diagram of the horizontal frame with its forces:
Figure 4.1:25.FBD of horizontal frame
 From the above we gate

 Mk = 29,924.544kNmm
 Mi = 11,828.094kNmm

 Fyi = 50.525kN
 Fyk = 15.583kN
 Fxk = 68.867kN
 θh = 77.25°
 Now find
Fy ′ k = Fyk ∗ cos θh + Fxk ∗ sin θh = 15.583 ∗ cos 77.25° + 68.867 ∗ sin 77.25°
 Fy ′ k = 70.608kN
 First find reaction force and moment
 Force along y-axis from the above figure 4.1-22
 +↑ ΣFy = 0
 Fy ′ k + Fyl − Fyi − Fyo = 0
 Fyo = Fyl + Fy ′ k − Fyi = Fyl + 70.608kN − 50.525kN
 Fyo = Fyl + 20.083kN………………….[1]
 Sum of bending moment at point ‘0’ clockwise is equal to zero
 ∑ M@o = 0,−Fy ′ k ∗ 71.788 + Mk + Mi + Fyi ∗ 379.312 − Fyl ∗
1767.768 = 0
 −70.608 ∗ 71.788 + 29,924.544 + 11,828.094 + 50.525 ∗ 379.312 −
Fyl ∗ 1767.768 = 0
 Fyl ∗ 1767.768mm = 55,649.431kNmm
 Fyl = 31.48kN
 Then Fyo = Fyl + 20.083kN = 31.48kN + 20.083kN = 51.563kN
 Bending moment at section x1-x1
 ∑ M@x1 = 0, , Fyo ∗ x1 + Mx1 = 0
 Mx1 = −Fyo ∗ x1
 M@x1 = 0 = M@o = −51.563 ∗ 0 = 0kNmm
 M@x1=71.788 = M@k = −51.563 ∗ 71.788 = −3,701.605kNmm
 ∑ M@x2 = 0, , Fyo ∗ x2 − Fy ′ k ∗ (x2 − 71.788) − Mk + Mx2 = 0
 Mx2 = −Fyo ∗ x2 + Fy ′ k ∗ (x2 − 71.788) + Mk

 M@x2=71.788 = M@k = −51.563 ∗ 71.788 + 70.608 ∗ (71.788 −

71.788) + 29,924.544
 M@k = 26,222.939kNmm
 M@x2=379.312 = M@i = −51.563 ∗ 379.312 + 70.608 ∗
(379.312 − 71.788) + 29,924.544
 M@i = 32,079.734kNmm
 ∑ M@x3 = 0, , Fyl ∗ x3 − Mx3 = 0
 Mx3 = Fyl ∗ x3
 M@x3 = 0 = M@l = 31.48 ∗ 0 = 0kNmm
 M@x1=1388.456 = M@i = 31.48 ∗ 1388.456 = 43,708.595kNmm
There fore
 Mxymax@k = 𝟐𝟗, 𝟗𝟐𝟒. 𝟓𝟒𝟒𝐤𝐍𝐦𝐦

 Mxymax@i = 𝟒𝟑, 𝟕𝟎𝟖. 𝟓𝟗𝟓𝐤𝐍𝐦𝐦
Bending moment Along x-z plane
 From the above we gate

 Fxi = 9.912kN
 Fyk = 15.583kN
 Fxk = 68.867kN
 θh = 77.25°

 Now find
Fx ′ k = Fyk ∗ sin θh − Fxk ∗ cos θh = 15.583 ∗ sin 77.25° − 68.867 ∗ cos 77.25°
 Fx ′ k = −0.0000109 ≈ 0
 +↑ ΣFz = 0
 Fzo − Fxi = 0
 Fzo = Fxi
 Fzo = 9.912kN
 ∑ M@x1 = 0, , − Fz0 ∗ x1 + Mx1 = 0
 Mx1 = Fzo ∗ x1
 M@x1=0 = M@o = 9.912kN ∗ 0mm = 0kNmm
 M@x1=71.788 = M@k = 9.912kN ∗ 71.788mm = 711.563kNmm
 M@x1=379.312 = M@i = 9.912kN ∗ 379.312mm = 3,759.741kNmm
There fore
 Mxzmax@k = 𝟕𝟏𝟏. 𝟓𝟔𝟑𝐤𝐍𝐦𝐦

 Mxzmax@i = 𝟑, 𝟕𝟓𝟗. 𝟕𝟒𝟏𝐤𝐍𝐦𝐦
Resultant moment at each point
 M@k = √Mxy@k 2 + Mxz@k 2 = √29,924.5442 + 711.5632 = 29,933.003kNmm
 M@i = √Mxy@i 2 + Mxz@i 2 = √43,708.5952 + 3,759.7412 = 43,870kNmm
 Vmax@o = √Vy@0 2 + Vz@0 2 = √51.5632 + 9.9122 = 𝟓𝟐. 𝟓𝟎𝟕𝐤𝐍
 Now maximum bending moment is take place at point ‘k’

 Mmax = 𝟒𝟑, 𝟖𝟕𝟎𝐤𝐍𝐦𝐦
 Vmax = 𝟓𝟐. 𝟓𝟎𝟕𝐤𝐍
𝐈 12

σy MN
280MN⁄ 2 MN
 σb = m
= 186.667 m2 = 186.667 N⁄mm2
1.5
b
M∗
b4 −h4
but, M = 43,870kNmm and b=h+2*t, h=b-2*t
12
b
 Let, b=20*t, t=20 and h=0.9*b
b
43,870kNmm∗
 186.667 N⁄mm2 = b4 −(0.9∗b)4
2
12
263,220kNmm∗b
 186.667 N⁄mm2 = 0.3439∗b4
 186.667 N⁄mm2 ∗ b3 = 765,396,917.7Nmm
 b3 = 4,100,333.309mm3
 b = 𝟏𝟔𝟎𝐦𝐦
b 160mm
 t = 20 = = 𝟖. 𝟎𝟎𝟑𝐦𝐦
20
standard table by using the value of b ≥ 160mm and t ≥ 8.003mm.
 b=175mm,
 t=9mm,
 h=b-2t=175mm-2*9mm=157mm
b 175mm
M∗ 43,870kNmm∗
 σb = 2
= 2
= 𝟏𝟑𝟗. 𝟒𝟓𝟐 𝐍⁄
b4 −h4 (175mm)4 −(157mm)4 𝐦𝐦𝟐
12 12

σy 280Mpa
 F. s new = σ = 139.452Mpa = 𝟐. 𝟎𝟎𝟖 > F. s old = 𝟏. 𝟓, so the design of horizontal
b
frame is safe due to bending load.

4.4.6.3. Horizontal Frame Subjected to Shear Stress
 The shear stress on the square hollow section on horizontal frame.
 Shear stress on the square hollow section on the horizontal frame is
Vmax
 τ= ,
A

Where
 Vmax = 52.507kN
Vmax 52.507kN 52.507kN

 τ= = = 1752 −1572 = 𝟖. 𝟕𝟖𝟔𝐌𝐩𝐚
A b2 −h2
1 1
 σp = 2 (σb ± √σb 2 + 4 ∗ τ2 ) = 2 (139.452Mpa ±
√(139.452Mpa)2 + 4 ∗ (8.786Mpa)2 )
 𝛔𝟏 = 𝟏𝟒𝟎. 𝟎𝟎𝟒𝐌𝐩𝐚 And 𝛔𝟐 = −𝟎. 𝟐𝟕𝟔𝐌𝐩𝐚, 𝛔𝟑 = 𝟎𝐌𝐩𝐚
1
 τmax = 2 (σ1 − σ2) = 1⁄2 (140.004Mpa + 0.276Mpa)
 τmax = 𝟕𝟎. 𝟏𝟒𝐌𝐩𝐚

σy 280Mpa
max
σy
 σ12 + σ22 − 2 ∗ σ1 ∗ σ2 = ( f.s )2
σy
 (140.004pa)2 + (−0.276Mpa)2 − 2 ∗ 140.004Mpa ∗ −0.276Mpa = ( f.s )2
σy 2
 ( f.s ) = 19,678.478Mpa2
σy
 = 140.28Mpa
F.s
σy 280Mpa
∴ 𝐝𝐞𝐬𝐢𝐠𝐧 𝐨𝐟 𝐡𝐨𝐫𝐢𝐳𝐨𝐧𝐭𝐚𝐥 𝐟𝐫𝐚𝐦𝐞 𝐢𝐬 𝐬𝐚𝐟𝐞 𝐝𝐮𝐞 𝐭𝐨 𝐛𝐞𝐧𝐝𝐢𝐧𝐠 𝐥𝐨𝐚𝐝, 𝐚𝐱𝐢𝐚𝐥 𝐥𝐨𝐚𝐝 𝐚𝐧𝐝 𝐬𝐡𝐞𝐚𝐫 𝐥𝐨𝐚𝐝.
4.4.7. Design of Connecting Frame

4.4.7.1. Material Selection for Connecting Frame
The material selection for connecting frame is low carbon (mild steel) with
GN
MN

MN
MN
Kg
 Density (ρ) = 7800 m3
Figure 4.1:26.3d view of connecting frame
4.4.7.2. Connecting Frame Subjected to Bending Moment

Figure 4.1:27.FBD of base body

 From horizontal frame we get the following values

 Fyo = 51.563kN
 Fzo = 7.785kN
 +↑ ΣFy = 0
 Fym − Fyo − Fyo + Fym = 0
 2Fym = 2Fy0
 Fym = Fyo = 𝟓𝟏. 𝟓𝟔𝟑𝐤𝐍
 Bending moment and shear force
Where 0 ≤ x1 ≤ 268.214mm
To find bending moment at each point take bending moment at point x1 anti clockwise is
zero
 ∑ M@x1 = 0, Mx − Fym ∗ x1 = 0
Mx = Fym ∗ x1
 𝐌𝐦@(𝐱𝟏=𝟎) = 51.563kN ∗ 0mm = 𝟎𝐤𝐍𝐦𝐦
 𝐌𝐨@(𝐱𝟏=𝟐𝟔𝟖.𝟐𝟏𝟒𝐦𝐦) = 51.563kN ∗ 268.214mm = 𝟏𝟑, 𝟖𝟐𝟗. 𝟗𝟏𝟖𝐤𝐍𝐦𝐦
 +↑ Σfy = 0, Vx + Fym = 0
Vx = −Fym = −51.563kN
 Vm@(x1=0mm) = Vo@(x1=468.214mm) = −Fym = −𝟓𝟏. 𝟓𝟔𝟑𝐤𝐍

Where 268.214mm ≤ x2 ≤ 668.214mm

To find bending moment at each point take bending moment at point x2 anticlockwise is zero
 ∑ M@x2 = 0, Mx − Fym ∗ x2 + 51.563kN ∗ (x2 − 268.214) = 0
 Mx = Fym ∗ x2 − 51.563kN ∗ (x2 − 268.214mm)
 𝐌𝐨@(x2=268.214mm) = 51.563kN ∗ 268.214mm − 51.563kN ∗
(268.214mm − 268.214mm) = 𝟏𝟑, 𝟖𝟐𝟗. 𝟗𝟏𝟖𝐤𝐍𝐦𝐦
 𝐌𝐨@(𝐱𝟐=𝟔𝟔𝟖.𝟐𝟏𝟒𝐦𝐦) = 51.563kN ∗ 668.214mm − 51.563kN ∗ (668.214mm −
268.214mm) = 𝟏𝟑, 𝟖𝟐𝟗. 𝟗𝟏𝟖𝐤𝐍𝐦𝐦
 +↑ Σfy = 0, Vx + Fym − 51.563kN = 0
Vx = Fym − 51.563kN = 51.563kN − 51.563kN = 0kN
 Vo@(x2=268.214mm) = Vo@(x2=668.214mm) = 𝟎𝐤𝐍
Where 0mm ≤ x3 ≤ 268.214mm

To find bending moment at each point take bending moment at point x2 anticlockwise is zero
 ∑ M@x3 = 0, Mx − Fym ∗ x3 = 0

 Mx = Fym ∗ x2
 𝐌𝐦@(x2=0mm) = 51.563kN ∗ 0mm = 𝟎𝐤𝐍𝐦𝐦
 𝐌𝐨@(x2=268.214mm) = 51.563kN ∗ 268.214mm = 𝟏𝟑, 𝟖𝟐𝟗. 𝟗𝟏𝟖𝐤𝐍𝐦𝐦
 +↑ Σfy = 0, −Vx + Fym = 0
Vx = Fym = 51.563kN
Vm@(x2=0mm) = Vo@(x2=268.214mm) = 𝟓𝟏. 𝟓𝟔𝟑𝐤𝐍
 Now maximum bending moment and shear force
 𝐌𝐦𝐚𝐱 = 𝟏𝟑, 𝟖𝟐𝟗. 𝟗𝟏𝟖𝐤𝐍𝐦𝐦
 𝐕𝐦𝐚𝐱 = 𝟓𝟏. 𝟓𝟔𝟑𝐤𝐍
𝐈 12
σy MN
280MN⁄ 2 MN
 σb = m
= 186.667 m2 = 186.667 N⁄mm2
1.5
b
M∗
b4 −h4
12
b
 Let, b=20*t, t=20 and h=0.9*b
b
13,829.918kNmm∗
 186.667 N⁄mm2 = b4 −(0.9∗b)4
2
12
82,979.508kNmm∗b
 186.667 N⁄mm2 = 0.3439∗b4
 186.667 N⁄mm2 ∗ b3 = 241,289,642.3Nmm
 b3 = 1,292,620.776mm3
 b = 𝟏𝟎𝟖. 𝟗𝟑𝟐𝐦𝐦
b 108.932mm
 t = 20 = = 𝟓. 𝟒𝟒𝟕𝐦𝐦
20
 b=175mm,
 t=6mm,

 h=b-2t=175mm-2*6mm=163mm
b 175mm
M∗ 13,829.918kNmm∗
 σb = 2
= 2
= 𝟔𝟐. 𝟓𝟗𝟖 𝐍⁄
b4 −h4 (175mm)4 −(163mm)4 𝐦𝐦𝟐
12 12

σy 280Mpa
 F. s new = σ = 62.598Mpa = 𝟒. 𝟒𝟕𝟑 > F. s old = 𝟏. 𝟓, so the design of connecting frame
b
is safe due to bending load.

4.4.7.3. Connecting Frame Subjected to Shear Stress
 The shear stress on the square hollow section on connecting frame.
 Shear stress on the square hollow section on the connecting frame is
Vmax
 τ= ,
A
Where
 Vmax = Fym = 51.563kN
F Fy′A 50.525kN 51.563kN
 τ=A= = = 1752 −1632 = 𝟏𝟐. 𝟕𝟏𝟑𝐌𝐩𝐚
A b2 −h2
1 1
 σp = 2 (σ𝑏 ± √σ𝑏 2 + 4 ∗ τ2 ) = 2 (62.598Mpa ±
√(62.598Mpa)2 + 4 ∗ (12.713Mpa)2 )
 𝛔𝟏 = 𝟔𝟓. 𝟎𝟖𝟐𝐌𝐩𝐚 And 𝛔𝟐 = −𝟐. 𝟒𝟖𝟒𝐌𝐩𝐚, 𝛔𝟑 = 𝟎𝐌𝐩𝐚
1
 τmax = 2 (σ1 − σ2) = 1⁄2 (65.082Mpa + 2.484Mpa)
 τmax = 𝟑𝟑. 𝟕𝟖𝟑𝐌𝐩𝐚

σy 280Mpa
max
σy
 σ12 + σ22 − 2 ∗ σ1 ∗ σ2 = ( f.s )2
σy
 (65.082)2 + (−2.484)2 − 2 ∗ 65.082 ∗ −2.484 = ( f.s )2
σy 2
 ( f.s ) = 4,565.164Mpa2

σy
 = 67.566Mpa
F.s
σy 280Mpa
∴ 𝐝𝐞𝐬𝐢𝐠𝐧 𝐨𝐟 𝐜𝐨𝐧𝐧𝐞𝐜𝐭𝐢𝐧𝐠 𝐟𝐫𝐚𝐦𝐞 𝐢𝐬 𝐬𝐚𝐟𝐞 𝐝𝐮𝐞 𝐭𝐨 𝐛𝐞𝐧𝐝𝐢𝐧𝐠 𝐥𝐨𝐚𝐝, 𝐚𝐱𝐢𝐚𝐥 𝐥𝐨𝐚𝐝 𝐚𝐧𝐝 𝐬𝐡𝐞𝐚𝐫 𝐥𝐨𝐚𝐝.
4.4.8. Design of Hook

4.4.8.1. Material Selection for Hook
The material selection for connecting frame is low carbon (mild steel) with
GN
 Young’s modulus of the elasticity (E) =207
m2
MN
MN
MN
Kg
 Density (ρ) = 7800 m3
Figure 4.1:28.3d view of hook

4.4.8.2. Bending Moment Subjected to the Hook

 Selection of hook
 All Crosby 320 Eye Hoist Hooks incorporate the following features:
• Designed with a 5:1 Design Factor.
• Every Crosby Eye Hook has a pre-drilled cam which can be equipped with a latch. Even
years after purchase of the original hook, latch assemblies can be added.
• Eye hooks are load rated.
• Available in carbon steel and alloy steel.
Table 4.1:5: Standard Dimensions of Crane Hook [13]

 By using work load limit (3ton) from the above standard table we have
A=200.66mm J=37.338mm
B=74.676mm K=33.274mm
C=146.558mm M=28.702mm
D=122.174mm O=34.544mm
F=50.8mm P=89.154mm
G=36.576mm Q=39.624mm
H=41.402mm T=38.862mm
 Load= total mass*gravity*service factor

 W = 3000kg ∗ 9.81m/s2 ∗ 1.25 = 36.787kN
Figure 4.1:29.FBD hook
 From the above figure 4.1:26 we have

F 50.8mm
 Ri = 2 = = 25.4mm
2
F
 R o = 2 + H = R i + H = 25.4mm + 41.402 = 66.802mm,
 h = H = 41.402mm
 b = T = 38.862mm
 Then the area of the cross section X-X is
 A = b ∗ h = 38.862 ∗ 41.402mm = 1,608.965mm2

 Radius of curvature of the neutral axis,

h
 Rn = R , for rectangular cross section
log𝑒 ( o )
Ri
h 41.402mm 41.402𝑚𝑚
 Rn = R = 66.802mm = = 42.815𝑚𝑚
log𝑒 ( o ) log𝑒(
25.4mm
) 0.967
Ri
 Radius of curvature of the centroid axis,

h
 R = R i + 2 , for rectangular cross section
h 41.402mm
 R = R i + = 25.4mm + = 46.101𝑚𝑚
2 2
 The distance between the centroid axis and neutral axis,

 e = R − R n = 46.101mm − 42.815mm = 3.286mm
 Distance between the load and the centroid axis,
 x = R = 46.101mm
 Bending moment about the centroid axis,
 M = W ∗ x = 36.787kN ∗ 46.101mm = 1,695.917MNmm
 Distance from the neutral axis to the inside fiber,
 yi = R n − R i = 42.815mm − 25.4mm = 17.415mm
 Distance from the neutral axis to outside fiber,
 yo = R o − R n = 66.802mm − 42.815mm = 23.987mm
 We know that direct tensile stress at section X-X,
W 36.787kN
 σdt = = 1,608.965mm2 = 22.864Mpa
A
 We know that maximum bending stress at the inside fiber,

M∗y 1,695.917kNmm∗17.415mm
 σbi = A∗e∗Ri = 1,608.965mm2 ∗3.286mm∗25.4mm
i
 σbi = 219.928Mpa
 We know that maximum bending stress at the outside fiber,
M∗y 1,695.917kNmm∗23.987mm
 σbo = A∗e∗Ro = 1,608.965mm2 ∗3.286mm∗66.802mm
o
 σbo = 115.18Mpa
 Resultant stress at the inside fibre
 σRi = σdt + σbi = 22.864Mpa + 219.928Mpa
 σRi = 𝟐𝟒𝟐. 𝟕𝟗𝟐𝐌𝐩𝐚(𝐭𝐞𝐧𝐬𝐢𝐥𝐞)

 Resultant stress at the outside fiber

 σRo = σdt − σbo = 22.864Mpa − 115.18Mpa
 σRo = −92.316Mpa = 𝟗𝟐. 𝟏𝟑𝟔𝐌𝐩𝐚(𝐜𝐨𝐦𝐩𝐫𝐞𝐬𝐬𝐢𝐯𝐞)
 We know that Shear stress at section X-X
W W
 τ = TANGENTIAL CROSS SECTIONAL AREA = A
𝑡
Where
 W=36.787kN
 A𝑡 = T ∗ K = b ∗ K = 38.862mm ∗ 33.274mm = 1,293.094mm2
Then
W 36.787kN
 τ = A = 1,293.094mm2 = 𝟐𝟖. 𝟒𝟒𝟗𝐌𝐩𝐚
𝑡
1 1
 σp = 2 (σRi ± √σRi 2 + 4 ∗ τ2 ) = 2 (242.792Mpa ±
√(242.792Mpa)2 + 4 ∗ (28.449Mpa)2 )
 𝛔𝟏 = 𝟐𝟒𝟔. 𝟎𝟖𝟏𝐌𝐩𝐚 And 𝛔𝟐 = −𝟑. 𝟐𝟖𝟗𝐌𝐩𝐚, 𝛔𝟑 = 𝟎𝐌𝐩𝐚
1
 τmax = 2 (σ1 − σ2) = 1⁄2 (246.081Mpa + 3.289Mpa)
 τmax = 𝟏𝟐𝟒. 𝟔𝟖𝟓𝐌𝐩𝐚

σy 280Mpa
 𝐅. 𝐬 𝐧𝐞𝐰 = 2∗τ = 2∗124.685Mpa = 1.123 > 1, it is 𝐬𝐚𝐟𝐞!
max
σy
 σ12 + σ22 − 2 ∗ σ1 ∗ σ2 = ( )2
f.s
σy
 (246.081)2 + (−3.289)2 − 2 ∗ 246.081 ∗ −3.289 = ( f.s )2
σy 2
 ( f.s ) = 62,185.397Mpa2
σy
 = 249.37Mpa
F.s
σy 280Mpa
 F. s new = 249.37Mpa = 249.37Mpa = 1.123 > 1, it is 𝐬𝐚𝐟𝐞!
∴ 𝐝𝐞𝐬𝐢𝐠𝐧 𝐨𝐟 𝐡𝐨𝐨𝐤 𝐢𝐬 𝐬𝐚𝐟𝐞 𝐝𝐮𝐞 𝐭𝐨 𝐛𝐞𝐧𝐝𝐢𝐧𝐠 𝐥𝐨𝐚𝐝, 𝐚𝐱𝐢𝐚𝐥 𝐥𝐨𝐚𝐝 𝐚𝐧𝐝 𝐬𝐡𝐞𝐚𝐫 𝐥𝐨𝐚𝐝.

4.4.9. Design of Bolt and Nut

4.4.9.1. Material Selection
 From the standard table SAE class 10.9 steel is the selected material for bolt and nut with
the following parameters
 Proof load=830Mpa
 Yield strength=940Mpa
 Tensile strength=1040Mp
Figure 4.1:30.3d view of bolt 2
Figure 4.1:31.3d view of nut 1

4.4.9.1.1. Design of Bolt and Nut for Connecting Back Hoist Body and Horizontal
Boom
4.4.9.1.1.1. Bolt subjected to Bending moment
Along x-z plane
 From the horizontal boom we gate

 Fxc = 218.959kN
 Force along z-axis from the above figure
 +↑ ΣFz = 0
 R1z + R2z − Fxc = 0
 R1z + R2z = Fxc = 218.959kN
 Sum of bending moment at point ‘1’ clockwise is equal to zero
 ∑ M@1 = 0,125mm ∗ 218.959kN − R2z ∗ 250mm = 0
 125mm ∗ 218.959kN = R2z ∗ 250mm
 R2z = 109.48kN
 R1z = Fxc − R2z = 218.959kN − 109.48 = 109.48kN
Therefore
Fxc∗L 218.959kN∗250mm
 Mxzmax@c = = = 13,684.938kNmm
4 4
 Vzmax = R1z = R2z = 109.48kN

Along x-y plane
 From the above we gate

 Fyc = 72.672kN
 Mc = 21240.423kNmm
 Force along y-axis from the above figure
 +↑ ΣFy = 0
 −R1y + R2y − Fyc = 0
 R2y − R1y = Fyc = 72.672kN
 ∑ M@1 = 0,125mm ∗ 72.672kN + Mc − R2y ∗ 250mm = 0
 125mm ∗ 72.672kN + 21240.423kNmm = R2y ∗ 250mm
 R2y ∗ 250mm = 30,324.423kNmm
 R2y = 121.298kN
 R1y = R2y − Fyc = 121.298kN − 72.672kN = 48.626kN
Bending moment at section x1-x1
 ∑ M@x1 = 0, , − R2y ∗ x1 + Mx1 = 0
 Mx1 = R1y ∗ x1
 M@x1 = 0 = M@1 = 48.626kN ∗ 0mm = 0kNmm
 M@x1=125mm = M@c = 48.626kN ∗ 125mm = 6,078.25kNmm
Bending moment at section x2-x2
 ∑ M@x2 = 0, , − R2y ∗ x2 + Mx2 = 0

 Mx2 = R2y ∗ x2
 M@x2 = 0 = M@2 = 121.298kN ∗ 0mm = 0kNmm
 M@x1=125mm = M@c = 121.298kN ∗ 125mm = 15,162.25kNmm
 Vmax = R2y = 121.298kN
Therefore
 Mxymax@c = 21240.423kNmm
 Vymax = R2y = 121.298kN
 Resultant moment at each point
 Mmax@c = √Mxz@c 2 + Mxy@c 2 = √15,162.252 + 21,240.4232 = 26,096.923kNmm
 Vmax@2 = √Vy@2 2 + Vz@2 2 = √121.2982 + 109.482 = 163.399kN
 Now maximum bending moment is take place at point ‘c’

 Mmax = 𝟐𝟔, 𝟎𝟗𝟔. 𝟗𝟐𝟑𝐤𝐍𝐦𝐦
 Vmax = 𝟏𝟔𝟑. 𝟑𝟗𝟗𝐤𝐍
𝐌∗𝐲 d πd4
𝐈 64
σy
 σb = σall = S.F , let S.F=1.5
940MN⁄ 2 MN
 σb = m
= 626.667 m2 = 626.667 N⁄mm2
1.5
d
M∗y M∗ 32∗M
 σb = = 2
πd4
=
I πd3
64
32∗26,096.923kNmm
 = 626.667 N⁄mm2
πd3
 d3 = 424,182.341mm3
 𝐝 = 𝟕𝟓. 𝟏𝟑𝟔𝐦𝐦
4.4.9.1.1.2. Shear load subjected to bolt

Vmax τy σy 940Mpa
 τall = πd2
, but τall = F.s = 2∗F.s = = 313.334Mpa
2∗1.5
4
163.399kN
 313.334Mpa = πd2
4

 d2 = 663.975mm2
 𝐝 = 𝟐𝟓. 𝟕𝟔𝟖𝐦𝐦
 For safe design take the larger one so
𝐝 = 𝟕𝟓. 𝟏𝟑𝟔𝐦𝐦
 But this value of “d” is not required in standard table, so we take “d” from standard table
by using the value of d ≥ 75.136mm
 𝐝 = 𝟖𝟎𝐦𝐦  𝐡 = 𝟓𝐦𝐦
 𝐃 = 𝟖𝟎. 𝟓𝐦𝐦  𝐇 = 𝟓. 𝟐𝟓𝐦𝐦
 𝐝𝐜 = 𝟕𝟎𝐦𝐦  𝐏 = 𝟏𝟎𝐦𝐦
Where
 d=major diameter of bolt  h=depth of bolt thread

 D=major diameter of nut  H=depth of nut thread
 dc =minor or core diameter of bolt  p=pitch
Now find bending moment
32∗M 32∗26,096.923kNmm
 σb = = = 519.182Mpa
πd3 π(80mm)3
Then find the new factor of safety
σy 940Mpa
F. S𝑛𝑒𝑤 = = = 1.81 > 1.5 it is safe!
σb 519.182Mpa
 Therefore the design of bolt and nut is safe due to bending load.

Figure 4.1:32.Hexagonal headed bolt with a nut and washer in position [14]
Now the outer diameter of the bolt and nut equal is given by from the above figure 4-23 as
follow
 dout = 2 ∗ d = 2 ∗ 80mm = 160mm

 Then thickness of the bolt and nut is given by from the above figure 4-23 as follow
 wbolt = 0.75 ∗ d = 0.75 ∗ 80 = 60mm
 wnut = d = 80mm
 Number of thread in the nut is given by
wnut 80mm
 nnut = p
= 10mm = 𝟖
 Length of thread bolt portion is given by

 L𝑡 = 2 ∗ d = 2 ∗ 80mm = 160mm
 Number of thread in the bolt is given by
L𝑡 160mm
 nbolt = = = 𝟏𝟔
p 10mm
 Total Length of bolt is given by

 Ltotal = wbolt + 250mm + wnut + 34.5mm = 60mm + 250mm +
80mm + 34.5mm
 Ltotal = 424.5mm
 The inner, outer diameter and width of washer is given by from the above figure 4-23 as
follow
 d𝑖𝑛 = d = 80mm
 d𝑜𝑢𝑡 = 2 ∗ d + 4 = 2 ∗ 80mm + 4mm = 164mm
 wwasher = 0.15 ∗ d = 0.15 ∗ 80mm = 12mm
 Shear Stress Across the Threads
 The average thread shearing stress for the bolt (τs ) is obtained by using the
relation :
FRc
τs =
πd ∗ b ∗ nbolt
Where
 b = width of thread section at the root

 FRc = √Fxc 2 + Fyc 2 = √218.9592 + 72.6722 = 230.704kN
F σy 940Mpa
b = πd∗τ Rc , but τs = τall = 2∗F.S = = 313.334Mpa
∗n
s bolt 2∗1.5
Now
230704N
b= = 0.183mm
π ∗ 80mm ∗ 313.334N/mm2 ∗ 16
 The average thread shearing stress for the nut (τs ) is obtained by using the
relation :
FRc
τs =
πD ∗ b ∗ nnut
F σy 940Mpa
b = πD∗τ Rc∗n , but τs = τall = 2∗F.S = = 313.334Mpa
s nut 2∗1.5
Now
230704N
b= = 0.364mm
π ∗ 80.5mm ∗ 313.334N/mm2 ∗ 8
So take the larger one for safe design b =0.364mm

 Compression or crushing stress on threads
 The compression or crushing stress between the threads for bolt (σc ) may be
obtained by using the relation :
FRc 230704N
σc = 2 = = 12.239Mpa
π(d2 − dc ) π(80mm2 − 70mm2 )
∗ nbolt ∗ 16
4 4
σc ≪≪ σy = 12.239Mpa ≪≪ 940Mpa it is safe due to crushing in the bolt
 The compression or crushing stress between the threads for nut(σc ) may be
obtained by using the relation :
FRc 230704N
σc = 2 = = 23.235Mpa
π(D2 − dc ) π(80.5mm2 − 70mm2 )
∗ nnut ∗8
4 4
σc ≪≪ σy = 23.235Mpa ≪≪ 940Mpa it is safe due to crushing in the nut

4.4.9.1.2. Design of Bolt and Nut for Connecting Hook and Horizontal Boom
4.4.9.1.2.1. Bolt subject to bending moment

 Force along y-axis from the above figure
 +↑ ΣFy = 0
 R1y + R2y − W = 0
 R1y + R2y = W = 29.43kN
 ∑ M@1 = 0,40mm ∗ 29.43kN − R2y ∗ 80mm = 0
 40mm ∗ 29.43kN = R2y ∗ 80mm
 R2y = 14.715kN
 R1y = W − R2y = 29.43kN − 14.715 = 14.715kN
Therefore
W∗L 29.43kN∗80mm
 Mmax@c = = = 588.6kNmm
4 4
 Vmax = R1y = R2y = 14.715kN

𝐌∗𝐲 d πd4
𝐈 64
σy
 σb = σall = S.F , let S.F=1.5
940MN⁄ 2 MN
 σb = m
= 626.667 m2 = 626.667 N⁄mm2
1.5
d
M∗y M∗ 32∗M
 σb = = πd4
2
=
I πd3
64

32∗588.6kNmm
 = 626.667 N⁄mm2
πd3
 d3 = 9,567.171mm3
 𝐝 = 𝟐𝟏. 𝟐𝟐𝟗𝐦𝐦
4.4.9.1.2.2. Bolt Subject to Shear Load

Vmax τy σy 940Mpa
 τall = πd2
, but τall = F.s = 2∗F.s = = 313.334Mpa
2∗1.5
4
14.715kN
 313.334Mpa = πd2
4
 d2 = 59.795mm2
 𝐝 = 𝟕. 𝟕𝟑𝟑𝐦𝐦
 For safe design take the larger one so
𝐝 = 𝟐𝟏. 𝟐𝟐𝟗𝐦𝐦
 But this value of “d” is not required in standard table, so we take “d” from standard table
by using the value of d ≥ 21.229mm and in order to fit the bolt with eye hook
(Q=39.624mm), so take the following values
 𝐝 = 𝟑𝟔𝐦𝐦  𝐡 = 𝟑𝐦𝐦
 𝐃 = 𝟑𝟔. 𝟓𝐦𝐦  𝐇 = 𝟑. 𝟐𝟓𝐦𝐦
 𝐝𝐜 = 𝟑𝟎𝐦𝐦  𝐏 = 𝟔𝐦𝐦
Where
 d=major diameter of bolt  h=depth of bolt thread

 D=major diameter of nut  H=depth of nut thread
 dc =minor or core diameter of bolt  p=pitch
Now find bending moment
32∗M 32∗588.6kNmm
 σb = = = 128.503Mpa
πd3 π(36mm)3
Then find the new factor of safety
σy 940Mpa
F. Snew = = = 7.315 > 1.5
σb 128.503Mpa

 Therefore the design of bolt and nut is safe due to bending load.
Figure 4- 1. Hexagonal headed bolt with a nut and washer in position [14]
 Now the outer diameter of the bolt and nut equal is given by from the above figure 4-24
as follow
 dout = 2 ∗ d = 2 ∗ 36mm = 72mm
 Then thickness of the bolt and nut is given by from the above figure 4-24 as follow
 wbolt = 0.75 ∗ d = 0.75 ∗ 36 = 27mm
 wnut = d = 36mm
 Number of thread in the nut is given by
wnut 36mm
 nnut = = =𝟔
p 6mm
 Length of thread bolt portion is given by

 L𝑡 = 2 ∗ d = 2 ∗ 36mm = 72mm
 Number of thread in the bolt is given by
L𝑡 72mm
 nbolt = = = 𝟏𝟐
p 6mm
 Total Length of bolt is given by

 Ltotal = wbolt + 80mm + wnut + 30.6mm = 27mm + 80mm + 36mm +
30.6mm
 Ltotal = 173.6mm

 The inner, outer diameter and width of washer is given by from the above figure 4-24 as
follow
 din = d = 36mm
 dout = 2 ∗ d + 4 = 2 ∗ 36mm + 4mm = 76mm
 wwasher = 0.15 ∗ d = 0.15 ∗ 36mm = 5.4mm
 Shear stress across the threads
 The average thread shearing stress for the bolt (τs ) is obtained by using the
relation :
W
τs =
πd ∗ b ∗ nbolt
Where
 b = width of thread section at the root
W σy 940Mpa
b = πd∗τ , but τs = τall = 2∗F.S = = 313.334Mpa
s ∗nbolt 2∗1.5
Now
29430N
b= = 0.07mm
π ∗ 36mm ∗ 313.334N/mm2 ∗ 12
 The average thread shearing stress for the nut (τs ) is obtained by using the
relation :
W
τs =
πD ∗ b ∗ nnut
W σy 940Mpa
b = πD∗τ , but τs = τall = 2∗F.S = = 313.334Mpa
s ∗nnut 2∗1.5
Now
29430N
b= = 0.14mm
π ∗ 36.5mm ∗ 313.334N/mm2 ∗ 6
So take the larger one for safe design b =0.14mm

 Compression or Crushing Stress on Threads

 The compression or crushing stress between the threads for bolt (σc ) may be
obtained by using the relation:
W 29430N
σc = = = 7.885Mpa
π(d2 − dc 2 ) π(36mm2 − 30mm2 )
∗ 12
∗ nbolt 4
4
σc ≪≪ σy = 7.885Mpa ≪≪ 940Mpa it is 𝐬𝐚𝐟𝐞 due to crushing in the bolt
 The compression or crushing stress between the threads for nut (σc ) may be
obtained by using the relation:
W 29430N
σc = 2 = = 14.448Mpa
π(D2 − dc ) π(36.5mm2 − 30mm2 )
∗ nnut ∗6
4 4
σc ≪≪ σy = 14.448Mpa ≪≪ 940Mpa it is 𝐬𝐚𝐟𝐞 due to crushing in the nut
4.4.10. Wheel Selection

Four wheels are need for the machine two wheels are at the back base of the machine and two
wheels are at the front base of the machine and the following parameters are as follows:
 Front wheel:
Material selection for front wheel is Steel-ductile
Figure 4.1:33.3d view of front wheel
 From the above total load of the machine the load carrying capacity of connecting frame,

 Fyl = 31.48 𝑘𝑁 Applied at each end of the connecting frame.

applied force
 The mass to carry the wheel = gravity
31480 N
 m= = 3208.97 kg
9.81
In order to carry the load from the connecting frame we are selecting the wheel from the standard.
Table 4.1:6.standard table of front wheel
Wheel Bore(mm) 30
Tread(mm) 100
Wheel Hub(mm) 108
Bearing type Tapper
Wheel material Steel Ductile
Wheel Dia (mm) 200
Load capacity( kg) 3600
Weight (kg) 11.35
 Rare Wheels:
Material selection for rare wheel is steel –Ductile plate swivel
Figure 4.1:34.3d view of rear caster wheel

 From the above total load of the machine the load carrying capacity of base body.
 Fym = 5156.3kN Applied at each end of the base body.
applied force
 The mass to carry the wheel = gravity
51563 N
 m= = 5256.17 kg
9.81
In order to carry the load from the horizontal frame we are selecting the wheel from the standard.
Table 4.1:7.standard table of rear wheel
Castor swivel radius (mm) 235
Castor fixing hole(mm) 16
Castor plate size(mm) 225*160
Castor hole center (mm) 210*160
Castor height (mm) 395
Tread (mm) 100
Wheel Dim (mm) 300
Load capacity(kg) 5500
Castor fixing Plate
Castor option Swivel
Wheel material Steel –Ductile
Bearing type Tapper
4.4.11. Welding
Welding is a fabrication process that joins materials, usually metals or thermoplastics, by causing
coalescence. This is often done by melting the work pieces and adding a filler material to form a
pool of molten material (the weld puddle) that cools to become a strong joint, but sometimes

pressure is used in conjunction with heat, or by itself, to produce the weld. This is in contrast with
soldering and brazing, which involve melting a lower-melting-point material between the work
pieces to form a bond between them, without melting the work pieces.
Mild steel is routinely welded, but it must be done under an inert gas atmosphere. The most reliable
method for Mild steel welding is the Tungsten Inert Gas (TIG) process. Gas tungsten arc welding
(GTAW), or tungsten inert gas (TIG) welding, is a manual welding process that uses a non-
consumable electrode made of tungsten, an inert or semi-inert gas mixture, and a separate filler
material. Especially useful for welding thin materials, this method is characterized by a stable arc
and high quality welds, but it requires significant operator skill and can only be accomplished at
relatively low speeds. TIG welding has the advantage of a small weld head, lower heat input is
required and filler metal is optional.
The welder must be careful not to apply too much heat for too long during welding. Welding of
thin gauge Mild steel requires a definite skill. Producing defect-free welds without overheating
the steel takes years of practice, no matter which welding process is used. Bad welds are difficult
to correct in Mild steel. It is more economical to get things done right the first time. In addition,
an experienced welder will know how to produce a good weld without overheating it. Overheating
causes precipitation of the chromium atoms away from the grain boundaries to form chromium
carbides, depleting the steel of its corrosion resistance.
Welding Filler Metals
The selection of the filler metal alloy for welding the Mild steels is based on the composition of
the mild steel. The various mild steel filler metal alloys are normally available as covered
electrodes and as bare solid wires.
Filler metal alloy for welding the various mild steel base metals are: Cr-Ni-Mn (AISI No. 308);
Cr-Ni-Austenitic (AISI No. 309, 310, 316, 317, and 347); Cr-Martensitic (AISI No. 410, 430);
Cr-Ferritic (AISI No. 410, 430, 309, 502). It is possible to weld several different mild steel base
metals with the same filler metal alloy.
Welding Procedures

For shielded metal arc welding; Covered electrodes for shielded metal arc welding must be stored
at normal room temperatures in dry area. These electrode coatings, of low hydrogen type, are
susceptible to moisture pickup. Once the electrode box has been opened, the electrodes should be
kept in a dry box until used.
The gas tungsten arc welding; process is widely used for thinner sections of mild steel. The 2%
tungsten is recommended and the electrode should be ground to a taper. Argon is normally used
for gas shielding; however, argon-helium mixtures are sometimes used for automatic applications.
The gas metal arc welding process is widely used for thicker materials since it is a faster welding
process. The spray transfer mode is used for flat position welding and this requires the use of argon
for shielding with 2% or 5% oxygen or special mixtures. The oxygen helps producing better
wetting action on the edges of the weld. For all welding operations, the weld area should be cleaned
and free from all foreign material, oil, paint, dirt, etc. The welding arc should be as short as possible
when using any of the arc processes.
Common welding joint types
(1) Square butt joint, (2) Single-V preparation joint, (3) Lap joint, (4) T-joint.

Figure 4.1:35.The cross-section of a welded butt joint
 To calculate the heat input for arc welding procedures, the following formula can be
used:
Where Q = heat input (kJ/mm), V = voltage (V), I = current (A), and S = welding speed (mm/min).
The efficiency is dependent on the welding process used, with shielded metal arc welding having
a value of 0.75, gas metal arc welding and submerged arc welding, 0.9, and gas tungsten arc
welding, 0.8.
4.4.12. Manufacturing Process

The knowledge of manufacturing processes is of great for a design engineer. The following are the
various manufacturing processes used in Mechanical Engineering.
1. Primary shaping processes: The processes used for the preliminary shaping of the
machine component are known as primary shaping processes. The common operations
used for this process are casting, forging, extruding, rolling, drawing, bending, shearing,
spinning, powder metal forming, squeezing, etc.
2. Machining processes: The processes used for giving final shape to the machine
component, according to planned dimensions are known as machining processes. The
common operations used for this process are turning, planning, shaping, drilling, boring,
reaming, sawing, broaching, milling, grinding, hobbling, etc.

3. Surface finishing processes: The processes used to provide a good surface finish for the
machine component are known as surface finishing processes. The common operations
used for this process are polishing, buffing, honing, lapping, abrasive belt grinding, barrel
tumbling, electroplating, super finishing, sherardizing, etc.
4. Joining processes: The processes used for joining machine components are known as
joining processes. The common operations used for this process are welding, riveting,
soldering, brazing, screw fastening, pressing, sintering, etc.
 Casting: It is one of the most important manufacturing process used in Mechanical
Engineering. The castings are obtained by remitting of ingots* in a cupola or some other
foundry furnace and then pouring this molten metal into metal or sand molds.
Table: manufacturing process for each components of the machine
Part name Material Required operation Required machine
Casting Sand casting

Facing Lath machine
Drilling Drill machine
Horizontal Boom Mild steel
Welding Welding machine
Finishing Sand paper
Painting Painting machine
Back hoist body Mild steel Facing Lath machine
Drilling Drill machine
Tapering Lath
Facing Lath machine
Tapering Lath machine
Mild steel

Horizontal frame Painting Painting machine

and base body

Back hoist support Mild steel Facing Lath machine
Mild steel Drilling Drill machine
Connecting frame
Facing Lath
Welding Electric arc
Casting Sand mold
Hook Mild steel Tapering Lath machine

Shaping Lath machine
Finishing Milling machine
Facing Lath machine
Turning Lath machine
Bolt and Nut SAE class 10.9 steel
Drilling Dill machine
Threading Milling machine

CHATER FIVE
5. RESULT AND DISCUSSION
5.1. Results
In this chapter, design results of parts and discussing the way how to install manual hydraulic hand
lift jib crane system.
 Design summary
 Design specification
 Maximum lifting height=2500mm
 Minimum lifting height =600mm
 θ1 = 65° and θ2 = 50°
 Boom length, Lb = 1250 mm
 Maximum mass to be lifted=3 ton=3000Kg
 Gravity= g = 9.81m⁄s2
 Load=mass*g=3000kg*9.81m⁄s 2 =29430N=29.430kN
 Parameters of the cylinder from standard table

 for three ton read from the appendix table
 Maximum height (Le ) =1176.274 mm
 Minimum height (Lr ) =668.274 mm
 Bore diameter =65mm

Table 5:1.result of all parts
Part name Material Mmax Vmax Dimension (mm)

(kNmm) (KN)
B H t L
Horizontal mild 32306.188 72.672 203 184 9.5 1250

boom steel
Back hoist mild 95265.414 187.728 250 226 12 1393.16

body steel
Horizontal mild 43870 52.507 175 157 9 1767.768
frame steel
Base body mild 11828.o94 50.525 120 108 6 936.428

steel
Back hoist mild 47623.707 15.583 175 157 9 1136.377
support steel
Connecting mild 13829.918 51.563 175 163 6 936.428
frame steel
mild Ri Ro Rn R Yi Yo
Hook steel
1695.917 124.685 25.4 66.802 42.815 46.101 17.415 23.685
d D dc h H P
SAE
26,096.923 163.399 80 80.5 70 5 5.25 10
Bolt and nut1 class
10.9 steel
Bolt and nut SAE 588.6 14.715 36 36.5 30 3 3.25 6
2 class
10.9 steel

5.2. ANSYS results for horizontal boom [input from appendix table 0:8.A]

5.3. ANSYS results for back hoist [input data from appendix table 0:7.A]

5.4. ANSYS results for hook [input data from appendix table 0:8.A]

5.5. Comparisons of ANSYS and manual result

1. Discussion on equivalent stress on the horizontal boom
 From Ansys equivalent stress result as follow
 σmax = 802.19 Mpa
 σmin = 3.914Mpa
 From manual maximum stress result as follow
 σmax = σ1 = 102.026 Mpa
 The maximum value of manual result is found between the maximum and minimum value
of ANSYS result. So the design is safe!
 From Ansys equivalent strain result as follow
 ∈max = 0.00388 m/m
 ∈min = 3.215 ∗ 10−5 m/m
 From manual maximum strain result as follow
𝜎𝑚𝑎𝑥 102.026Mpa
 ∈max = =
E 207Gpa
 ∈𝑚𝑎𝑥 = 0.000493
 The maximum value of manual strain result is found between the maximum and minimum
value of ANSYS strain result. So the design is safe!
 From Ansys the deflection result as follow
 ∆max = 3.64mm
 ∆min = 0mm
 From manual maximum deflection result as follow is
 ∆max =∈max ∗ L
 ∆max = 0.000493 ∗ 1250mm
 ∆max = 0.616mm
 The maximum value of manual deflection result is found between the maximum and
minimum value of ANSYS deflection result. So the design is safe!
2. Discussion on equivalent stress on the back hoist body
 From Ansys equivalent stress result as follow
 σmax = 6167Mpa
 σmin = 0.7459Mpa

 From manual calculation maximum stress result is;

 σmax = σ1 = 119.826Mpa
 The maximum value of manual stress result is found between the maximum and minimum
value of ANSYS result. So the design is safe!
 From ansys equivalent strain result as follow
m
 ∈max = 0.03658 m
 ∈min = 3.828 ∗ 10−6 m/m

 From manual maximum strain result as follow
σmax 119.826Mpa
 ∈max = =
E 207Gpa
 ∈max = 0.000579
 The maximum value of manual strain result is found between the maximum and minimum
value of ANSYS strain result. So the design is safe!
 From ANSYS the deflection result as follow
 ∆max = 16.78mm
 ∆min = 0mm
 From manual calculation the maximum deflection result of back hoist body is;
 ∆max =∈max ∗ L
 ∆max = 0.000579 ∗ 1393.16mm
 ∆max = 0.806mm
 The maximum value of manual deflection result is found between the maximum and
minimum value of ANSYS deflection result. So the design is safe!
3. Discussion on equivalent stress on the hook
 from Ansys equivalent stress result is;
 σmax = 167.19Mpa
 σmin = 0.000677Mpa
 From manual calculation maximum stress result is;
 σmax = 242.792Mpa

 The maximum value of manual stress result is not found between the maximum and
minimum value of ANSYS result. So the design of hook is highly stress cross section. So
the designer recommended that avoid over load more than 3 ton.
 From Ansys equivalent strain result for hook is;
m
 ∈max = 8.186 ∗ 10−4 m
 ∈min = 3.276 ∗ 10−9 m/m

 From manual maximum strain result for hook is; as follow
σmax 242.792Mpa
 ∈max = =
E 207Gpa
 ∈max = 0.00117
 The maximum value of manual strain result is not found between the maximum and
minimum value of ANSYS strain result. So the design of hook is highly strain cross section.
So the design is safe!
 From ANSYS the deflection result as follow
 ∆max = 0.0003226mm
 ∆min = 0mm
 From manual calculation the maximum deflection result of back hoist body is;
D−25
 ∆max =∈max ∗ 2
80−25
 ∆max = 0.0017 ∗ 2
 ∆max = 0.04675mm
 The maximum value of manual deflection result is not found between the maximum and
minimum value of ANSYS deflection result. So the design of hook is highly strain.
We recommend that another designer select above our factor of safety in order maintain this
problems. And also our machine is flexible or movable we recommend to use this machine garages
specially Jovani garages it is located on autoparko in Gondar when we at observation time in Jovani
garage, we saw our machine but it is fixed and out of use instead the company uses baranco.

5.6. Discussion
Generally the result from the above table tells us, good, easily, available material selection of
horizontal boom, back hoist support, connecting frame, horizontal fame, base body, nuts and bolts
are compatible each other to resist the direct stress, bending moment and shear stress that occurred
during assemble and disassemble of manually hydraulic hand lift jib crane. It also tells us to reduce
the deformation of components compatibility of each components must be considered (i.e
horizontal boom, back hoist support, bolt with nut). So the component of the manually hydraulic
hand lift jib crane assembly can be aligned properly.
When we compare our design to the existing manually hydraulic hand lift jib crane the stress and
fracture of component is reduced and the stability of the machine is increase by aligned of
horizontal frame by 45 degree. The carrying capacity and lifting height of the machine is increasing
by adding some component. Bolt is long and strong to resist the axial load, the selection of caster
wheel is best and standard to resist the maximum applied load caused by the manually hydraulic
hand lift jib crane machine. In order to move the loading machine at most two people are required.

CHAPTER SIX
6. COST ANALYSIS
A system which systematically recodes all the expenditure to determine the cost of manufactured
products is called costing. The total cost on manual hydraulic hand lift jib crane made up of four
main elements;
1. material cost
2. expense cost (manufacturing cost)
3. labor cost
4. purchase cost
6.1. Material Cost for Manual Hydraulic Hand Lift Jib Crane
Table 6:1.material cost of each component
Material cost
Part name Material Qty Cost ρ(kg b or h or L V M Cost
type (U) /m3 ) Do Di (m) (m3) (kg) ($)
($/kg) (m) (m)
Horizontal Mild 1 2.6 7800 0.203 0.184 1.25 0.009191 71.6917 186.399
Boom steel 5
Back hoist Mild 1 2.6 7800 0.25 0.226 1.3932 0.015915 124.140 322.766
steel 5
Base body Mild 1 2.6 7800 0.12 0.108 0.9364 0.002562 19.984 51.958
steel
Back hoist Mild 2 2.6 7800 0.175 0.157 1.1364 0.01358 105.939 275.441
support steel
Horizontal Mild 2 2.6 7800 0.175 0.157 1.7678 0.02113 164.794 428.464
frame steel
Connectin Mild 1 2.6 7800 0.175 0.163 0.9364 0.003798 29.6255 77.025
g frame steel

Bolt 1 SAE 1 4 7920 0.16 - 0.4245 0.008531 67.5635 270.254

class
10.9
steel
Bolt 2 SAE 1 4 7920 0.072 - 0.1736 0.000706 5.595 22.380
class
10.9
steel
Nut 1 SAE 1 4 7920 0.16 0.08 0.08 0.1206 9.549 38.196
class
10.9
steel
Nut 2 SAE 1 4 7920 0.072 0.036 0.036 0.00011 0.87 3.48
class
10.9
steel
Hook Mild 1 2.6 7800 - - - 2 5.2
steel
Total cost $ 1681.563
 Where
 b= base of each material
 h= height of each material
 L=length of each material
 D= diameter of each material
 Qty= quantity of each material
 ρ =density of each material
 U=($/kg)
 V = (b2 − h2 ) ∗ L for square hollow cross-section
π
 V= ∗ (Do2 − Di2 ) ∗ L for circular hollow cross-section
4

π
 V= ∗ Do2 ∗ L for circular solid cross-section
4
 M= ρ∗V
 Cost = M ∗ U
6.2. Manufacturing Cost and Labor Cost

 Manufacturing cost are cost required when different operation are performed on the raw
marital.
 Labor cost are cost to pay the labor worker.
Table 6:2.manufacturing & labor cost of each material
manufacturing
Part name cost($ ) Labor cost($)
Horizontal Boom 8 2
Back hoist 8 2
Base body 4 1
Back hoist support 4 1
Horizontal frame 6 1.75
Connecting frame 4 1
Bolt 1 6 2
Bolt 2 3 1
Nut 1 2 0.5
Nut 2 1 0.25
Hook 5 2
Total cost $ 47.00 $14.50
6.3. Purchase Cost;

 The wheel and hydraulic cylinder of manually hydraulic hand lift jib crane are
Purchase.

Table 6:3.purchase cost
Part name Load range(kg) Qty Purchase cost

Hydraulic 3000 1 $500
cylinder
Rare Wheel 5,256.2 2 $100
Front Wheel 3,209 2 $70
Total
6.4. Total Cost for Manually Hydraulic Hand Lift Jib Crane Machine
 Total cost is the sum of all cost required.
 𝐓𝐨𝐭𝐚𝐥 𝐜𝐨𝐬𝐭 = material cost + manufacturing cost + labor cost +
purchase cost
 𝐓𝐨𝐭𝐚𝐥 𝐜𝐨𝐬𝐭 = $ 1681.563 + $47 + $14.5 + $500 + $100 + $70
 𝐓𝐨𝐭𝐚𝐥 𝐜𝐨𝐬𝐭 = 𝟐𝟒𝟏𝟑. 𝟎𝟔𝟑$

CHAPTER SEVEN
7. CONCLUSION AND RECOMMENDATION
7.1. Conclusion
The design of manual hydraulic hand lift jib crane machine with a maximum lift mass of 3 ton
(3000kg), maximum lift height of 2500mm & minimum lift height of 600mm is important for the
application of garages and small and micro enterprises in Ethiopia. This crane is suitable for
loading and unloading heavy material workshops and it is busy else-where in rapid garages these
are required for handling engines and its parts. These cranes can also be used to carry liquids in
containers and moving parts from place to place by pumping the hydraulic handle part and pushing
the machine manually.
7.2. Recommendation
Because of this machine becomes manual, simple to lift up loads by pumping and it doesn’t ask
qualification of employees, those garages and small and micro enterprises should be use it to
accelerate and to make easily the work activity.
Some components of the machine are made up of from different steel class therefore the user
should be prevent from rest in order to keep their life time. Because if they have got rest, they
could be malfunction.
Capacity of the machine is three tons therefore the users should not use above its capacity. If the
load is above three ton there may be bending of the component such as boom and buckling of hoist
body.
Finally, we recommend that IOT director should see this project and install this project for the
benefit of material handling. Its benefit can be seen in terms of high safety of material during lifting
and moving. This project paper can also be used as guideline for design of manually hydraulic
hand lift jib crane and we do all the Ansys results in static load condition so we recommend another
designer uses dynamic load for real results.

REFERENCE
[1] www.davidround.com/company-history/.
[2] https://www.indiamart.com/proddetail/mobile-floor-jib-crane-3684882555.html.
[3] Coulton, J. J. (1974), "Lifting in Early Greek Architecture", The Journal of Hellenic
Studies, 94: 1–19, doi:10.2307/630416,JSTOR 630416, p.7.
Studies, 94: 1–19, doi:10.2307/630416,JSTOR 630416, pp.14f.
Studies, 94: 1–19, doi:10.2307/630416,JSTOR 630416, p.16.
[6] The UK business market LTD, “design and manufacturing of heavy duty Folding Workshop
Crane machine”, 2018. Or https://www.UKL TD- cranes.com/English/workshop- cranes.
[7] Nationwide industrial supply, “design and manufacturing of beech counterweighted crane
machine”, 2018. Or https://www.nationwideindustrial supply cranes.com/English/beech
counterweighted - cranes.
[8] Rockwell Hoisto Cranes Private Limited, “design and manufacturing of manual mobile
material handling machine”. Or https://www. RockwellHoistoCranes(Pv.t)Ltd supply
cranes.com/mobile material handling- cranes.
[9] Selby Engineering and Lifting Safety LTD, “design and manufacturing of mobile jib crane
machine” Or https://www.liftingsafety.co.uk/product/transportable-mini-cranes-3141.html.
[10] Asmita Jadhav, B.E. Mechanical (Pune University), “Design and development of Rotating
Floor Crane”.
[11] Chaitra C. Danavatimath, Prof. H. D. Sarode (P.G.student.Dpartment of Mechanical

Engineering), “Finite Element Analysis and Optimization of Jib Crane Boom” international
Journal of Innovative Research in Science, Engineering and Technology (IJIRSET), Volume: 6,
Issue: 07, Page 1-8 | July -2017.

[12] Okolie Paul Chukwulozie et al (2015), “Design and Analysis of a mobile floor crane” British
Journal of Applied science and Technology (BJAST), Volume: 13, Issue: 05, Page 1-9 | Nov -2015.
[13] https://www.grosbygroupink.co.uk.
[14] Department of Mechanical Engineering Indian Institute of Technology, Machine drawing,

third edition. K.L.Narayana-et al, 2006, chapter 5, page 88, fig 5.15.

DECLARATION
We undersigned, declare that the thesis comprises our own work. In compliance with
internationally accepted practice, we have acknowledge and referred all materials used in this
work. We understand that non-adherence to the principle of academic honesty and integrity,
misrepresentation/fabrication of any idea/ data/ fact/source will constitute sufficient ground for
disciplinary action by the university and can also evoke penal action from the source which have
not been properly cited or acknowledged.
NAME ID NO SIGNATURE DATE
1. YINAGER YALEW 0858/06

2. ZEKIROSE MIHERETAB 0891/06
This thesis has been submitted for examination with my approval as a university adviser.
ADVISOR NAME:
ADVISOR’S SIGNATURE:

APPENDICES
Table 0:1.A. typical mechanical and physical properties for engineering metals
material Young’s Shear Elastic Shear Tensile Shear Density

modulus modulus limit 𝛔𝐲 Yield strength Ultimate
𝛒(𝐤𝐠
of G strength 𝛔𝐮𝐭 strength
(𝐌𝐍⁄ 𝟐 /𝐦𝟑 )
elasticity 𝐦 𝛕𝐲 𝛕𝐮𝐭 (𝐌𝐍⁄ 𝟐 )
(𝐆𝐍⁄ 𝟐 ) (𝐌𝐍⁄ 𝟐 ) 𝐦
E(𝐆𝐍⁄ 𝟐 𝐦 ) 𝐦
𝐦 (𝐌𝐍⁄ 𝟐
𝐦
)
)
Aluminum 69 26 230 - 390 240 2770

alloy
brass 102 38 - - 350 - 8350
bronze 115 45 210 - 310 - 7650
Cast iron 90 41 - - 210 - 7640

Grey
Cast iron 170 83

Malleable
248 166 370 330 7640
Low 207 80 280 175 480 350 7800

carbon
(mild
steel)

Nickel- 208 82 1200 650 1700 950 7800

chrome
steel
titanium 107 40 480 - 551 - 4507
magnesiu 45 17 262 - 379 165 1791

m
[Source: University of Warwick and United Kingdom, introduction to the mechanics of elastic
and plastic deformation of solid and structural material, third edition. Ox28DPE.JHearn, 1997,
Apendix1, page 534]
Table 0:2.A. standard table of hydraulic cylinder
Jack Strok Minimu Maxi Plun Base Saddle Wei Model bore
e m mum ger dimension ght diamete
Capa Diame Number
r
city (In) Height Heigh Dia (In)L*W ter (Ibs
t mete ) (In)
(ton) (In) (in)
r
(In)
(In)
1.5 18 21.72 39.72 .88 3.63*5 .75 12.8 *EBJL- 1.275

15GC
2 3.74 6.89 13.39 .87 4.02*3.78 .83 6.6 EBJL- 1.7

2GC
3 20 26.31 46.31 1.12 4.25*5.5 1.12 22 *EBJL- 2.55

3GC
4 4.72 7.68 15.16 1.11 4.41*4.13 1.03 9.3 EBJ-4GC 2.55

6 5.12 8.27 16.54 1.34 4.72*4.49 1.19 12.1 EBJ-6GC 2.57
8 5.51 8.66 17.32 1.50 4.92*4.69 1.34 13.7 EBJ-8GC 2.57
12 6.10 9.45 18.70 1.7 5.31*5.12 1.58 17.6 EBJ12G 2.9

C
12 3.03 6.10 10.83 1.7 5.31*5.12 1.58 14.6 *EBJS- 2.9

12GC
15 5.91 9,45 18.50 1.89 5.71*5.43 1.70 20.7 EBJ- 3

15GC
20 6.10 9.84 19.09 2.09 6.10*5.71 1.82 25.1 EBJ- 3.149

20GC
20 3.11 6.50 11.22 2.09 6.10*5.71 1.82 19.8 *EBJS- 3.149

20GC
20 6.89 11.22 18.11 2.80 7.48*5.91 2.72 56.9 *EBJ- 3.149

30GC
50 4.13 9.25 13.78 3.35 10.04*7.48 3.15 92.6 *EBJ- 3.228

50GC
100 5.91 12.28 18.38 4.89 11.81*9.45 3.94 198. *EBJ- 3.349
9 100GC
[Source: www.enerpac.com]
Table 0:3.A. Dimensions and cross-sectional properties Square hollow sections
H= height, B=base T=thickness

H*B T H*B T H*B T
(mm*mm) (mm) (mm*mm) (mm) (mm*mm) (mm)
25*25 2 60*60 5 120*120 3
25*25 2.5 70*70 2.5 120*120 4
25*25 3 70*70 3 120*120 5
30*30 2 70*70 4 120*120 5.6
30*30 2.5 70*70 5 140*140 4
30*30 3 80*80 2.5 140*140 5
40*40 2 80*80 3 140*140 5.6
40*40 2.5 80*80 4 140*140 6
40*40 3 80*80 5 150*150 4
40*40 4 80*80 6 150*150 5
50*50 2 90*90 2.5 150*150 6
50*50 2.5 90*90 3 150*150 7.1
50*50 3 90*90 4 160*160 4
50*50 4 90*90 5 160*160 5
50*50 5 90*90 6 160*160 6
60*60 2 100*100 2.5 160*160 12.5
60*60 2.5 100*100 3 175*175 6
60*60 3 100*100 4 175*175 9

60*60 4 100*100 5 180*180 5
70*70 3 120*120 5 180*180 6
70*70 3.6 120*120 6 180*180 10
75*75 3.2 120*120 6.3 203*203 9.5
75*75 4 120*120 8 250*250 12
[Source: www.consteel.com.sg]
Table 0:4.A. specification for steeled in millimeter series screws and bolts
SAE Proof load Yielded Tensile Elongatio Reductio Core

class Strength( strength(Ma strength(Ma n n of area hardness
Map) p) p) Minimum minimu Rockwell
(%) m (%)
min max
4.6 225 240 400 22 35 B67 B87
4.8 310 - 420 - - B71 B87
5.8 380 - 520 - - B82 B95
8.8 600 660 830 12 35 C23 C34
9.8 650 900 - - C27 C36
10.9 830 940 1040 9 35 C33 C39
12.9 970 1100 1220 8 35 C38 C44
[Source: society of automotive engineers standardJ1199 (1979)]
Table 0:5.A. Basic dimensions for square threads in mm (Normal series) according to IS: 4694 –
1968 (Reaffirmed 1996)

Normal series
Major diameter Minor diameter (dc) Pitch (p) Depth of thread
Bolt (d) Nut (D) Bolt (h) Nut (H)
22 22.5 17 5 2.5 2.75
24 24.5 19
26 26.5 21
28 28.5 23
30 30.5 24 6 3 3.25
32 32.5 26
34 34.5 28
36 36.5 30
38 38.5 31 7 3.5 3.75
40 40.5 33
42 42.5 35
44 44.5 37
46 46.5 38 8 4 4.25
48 48.5 40
50 50.5 42
52 52.5 44
55 55.5 46 9 4.5 5.25

58 58.5 49
60 60.5 51
62 62.5 53
65 65.5 55 10 5.25
68 68.5 58 5
70 70.5 60
72 72.5 62
75 75.5 65
78 78.5 68
80 80.5 70
82 82.5 72
[Source: a text book of machine design by R.S.KHURMI and J.K.GUPTA, 2005; chapter 17
table 17.2, page 628]
Table 0:6.A. Input Data for Ansys results of Horizontal Boom

Model (A4) > Geometry > Parts
Object Name Solid Solid
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No

Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference Temperature By Environment
Material
Assignment Mild steel
Nonlinear Effects Yes
Thermal Strain Effects Yes
Bounding Box
Length X 0.203 m
Length Y 0.203 m
Length Z 1.0977 m 0.15227 m
Properties
Volume 8.0716e-003 m³ 1.1196e-003 m³
Mass 62.959 kg 8.7332 kg
Centroid X -2.2476e-002 m
Centroid Y 7.6148e-002 m
Centroid Z -0.47323 m 0.15177 m
Moment of Inertia Ip1 6.716 kg·m² 7.1504e-002 kg·m²
Moment of Inertia Ip2 6.716 kg·m² 7.1504e-002 kg·m²
Moment of Inertia Ip3 0.78766 kg·m² 0.10926 kg·m²
Statistics
Nodes 4416 2080

Elements 608 260
Mesh Metric None
Model (A4) > Static Structural (A5) > Loads

Object Name Fixed Support Force Force 2
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 1 Face 1 Edge
Definition
Type Fixed Support Force
Suppressed No
Define By Components
Coordinate System Global Coordinate System
X Component 0. N (ramped)
Y Component 1.021e+005 N (ramped) -29430 N (ramped)
Z Component -2.1896e+005 N (ramped) 0. N (ramped)
Mild steel > Constants

Density 7800 kg m^-3
Mild steel > Isotropic Elasticity

Temperature C Young's Modulus Pa Poisson's Ratio Bulk Modulus Pa Shear Modulus Pa
2.07e+011 0.3 1.725e+011 7.9615e+010
Table 0:7.A. Input Data for Ansys results of back hoist body

Object Name Solid Solid Solid

State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Material
Bounding Box
Length X 0.25 m
Length Y 0.60216 m 0.52733 m 0.26367 m
Length Z 0.25 m
Properties
Volume 6.8791e-003 m³ 6.0243e-003 m³ 3.0121e-003 m³
Mass 53.657 kg 46.989 kg 23.495 kg
Centroid Y -0.83784 m -0.2731 m 0.1224 m
Centroid Z 0.27639 m
Moment of Inertia Ip1 2.1292 kg·m² 1.5336 kg·m² 0.35848 kg·m²

Statistics
Nodes 4224 3916 2808
Elements 572 528 364
Mesh Metric None

Fixed Fixed
Object Name Force Force 2 Moment
Support Support 2
State Fully Defined
Scope
Scoping
Geometry Selection
Method
Geometry 1 Edge
Definition
Type Fixed Support Force Moment
Suppressed No
Define By Components Vector
Coordinate
Global Coordinate System
System
1.341e+005 N -2.3707e+005 N
Y Component
(ramped) (ramped)
1.8773e+005 N
Z Component -46512 N (ramped)
(ramped)
-32306 N·m
Magnitude
(ramped)
Direction Defined
Behavior Deformable

Advanced
Pinball Region All


2.07e+011 0.3 1.725e+011 7.9615e+010
Table 0:8.A. Input Data for Ansys results of back hoist body
Object Name Solid
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Material
Bounding Box
Length X 0.14448 m
Length Y 0.20066 m

Length Z 3.8862e-002 m
Properties
Volume 4.6659e-004 m³
Mass 3.6394 kg
Centroid Y 2.5643e-002 m
Centroid Z -1.9431e-002 m
Moment of Inertia Ip1 1.1718e-002 kg·m²
Statistics
Nodes 2041
Elements 999
Mesh Metric None

Object Name Fixed Support Force
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 2 Faces 1 Face
Definition
Type Fixed Support Force
Suppressed No
Define By Components
Coordinate System Global Coordinate System

Y Component -29430 N (ramped)
Z Component 0. N (ramped)


2.07e+011 0.3 1.725e+011 7.9615e+010

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June 14 Gondar, Ethiopia

EXAMINER’S APRROVAL PAGE

EXTERNAL EXAMINER SIGNATURE DATE

INTERNAL EXAMINER SIGNATURE DATE

ADVISOR SIGNATURE DATE

CHAIRPERSON SIGNATURE DATE

ABSTRACT ................................................................................................................................... iii

TABLE OF CONTENT ................................................................................................................. iv

LIST OF FIGURES ..................................................................................................................... viii

LIST OF TABLES .......................................................................................................................... x

NOMENCLATURE AND ABBREVIATION .............................................................................. xi

CHAPTER ONE ............................................................................................................................. 1

1.1. Background of the Study ................................................................................................ 1

1.2. Statement of the Problem ................................................................................................ 2

1.3. Objective of the Project .................................................................................................. 3

1.3.1. General Objective: .................................................................................................... 3

1.3.2. Specific Objective ..................................................................................................... 3

1.4. Significance of the Project .............................................................................................. 3

1.5. Scope of the Project ........................................................................................................ 3

1.6. Limitation of the Project ................................................................................................. 4

CHAPTER TWO ............................................................................................................................ 5

2. LITERATURE REVIEW ........................................................................................................ 5

2.1. Introduction to Design and Development of Product ..................................................... 5

2.1.1. Application of Cranes ............................................................................................... 7

2.1.2. Fluid Power Systems................................................................................................. 8

2.2. Current Theories and Design Done On Jib Crane .......................................................... 9

2.4. Design Approach With Regard to Our Project ............................................................. 15

2.5. Available Standards Pertinent to Our Design ............................................................... 15

2.6. REASON FOR SELECTING OUR TOPIC ................................................................. 15

CHAPTER THREE ...................................................................................................................... 16

3. METHODOLOGY OF THE PROJECT ............................................................................... 16

3.1. Data Collection Method ................................................................................................ 17

3.2.1. Design Matrix ......................................................................................................... 29

3.2.2. Summary of Literature Review ............................................................................... 31

3.3. Selection of Materials for Engineering Purposes .......................................................... 31

3.4. Design Part and Stress Analysis ................................................................................. 32

3.6. Result and Discussion ................................................................................................... 32

3.7. Cost Analysis of our Design ......................................................................................... 32

3.8. Recommendation and Conclusion ................................................................................ 32

CHAPTER FOUR ......................................................................................................................... 33

4. DESIGN ANALYSIS ............................................................................................................ 33

4.1. Data Gathering .................................................................................................................. 33

4.1.1. Interview ................................................................................................................. 33

4.1.3. Observation ............................................................................................................. 34

4.2. Selection of Hydraulic Bottle Jack ............................................................................... 36

4.2.1. Oil Type .................................................................................................................. 37

4.3.1. Geometrical Analysis of the Machine..................................................................... 37

4.3.2. Parameters of the Cylinder from Standard Table ................................................... 38

4.4. Design of Components of Machines ............................................................................. 43

4.4.1. Design of Horizontal Boom .................................................................................... 43

4.4.2. Design of Back Hoist Body .................................................................................... 49

4.4.3. Design of the Horizontal Frame and Base Body .................................................... 60

4.4.4. Design of Base Body .............................................................................................. 62

4.4.4.6. Deflection of Base Body ..................................................................................... 69

4.4.5. Design of Back Hoist Support ................................................................................ 70

4.4.6. Design of Horizontal Frame.................................................................................... 76

4.4.7. Design of Connecting Frame .................................................................................. 82

4.4.8. Design of Hook ....................................................................................................... 88

4.4.9. Design of Bolt and Nut ........................................................................................... 93

4.4.10. Wheel Selection................................................................................................. 104

4.4.11. Welding ............................................................................................................. 106

4.4.12. Manufacturing Process ...................................................................................... 109

CHATER FIVE ........................................................................................................................... 112

5. RESULT AND DISCUSSION ............................................................................................ 112