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Final Last PDF
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.
2.
3.
4.
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.
iii
TABLE OF CONTENT
Content page
ACKNOWLEDGEMENT .............................................................................................................. ii
1. INTRODUCTION ................................................................................................................... 1
1.7. Assumptions.................................................................................................................... 4
iv
2.3. Importance of Our Design in Engineering Applications .............................................. 14
3.2. Comparison of Previous Work Related to Our Project List in the Literature Review . 18
3.5. Draw Part and Assembly Drawing by using Solid Work Software and Check the
Deformation by using ANSYS Software. ................................................................................. 32
4.1.2. Questionnaires......................................................................................................... 34
v
4.3. Design Specification ..................................................................................................... 37
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
vi
CHAPTER SIX ........................................................................................................................... 121
6.1. Material Cost for Manual Hydraulic Hand Lift Jib Crane .......................................... 121
6.4. Total Cost for Manually Hydraulic Hand Lift Jib Crane Machine ............................. 124
vii
LIST OF FIGURES
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
x
NOMENCLATURE AND ABBREVIATION
kg Kilogram kg
UK United kingdom -
Max Maximum -
Min Minimum -
mm Millimeter mm
g Gravity m/s 2
kN Kilo newton kN
Lb boom length mm
@ At -
W Weight kN
D Bore diameter mm
xi
Fp Force acting on the piston kN
ρ Density kg/m3
m mass Kg
F. s Factor of safety -
xii
K The least radius of gyration of the section mm
a Ranking constant -
xiii
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
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].
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.
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.
1.7. 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.
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.
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.
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.
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.
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.
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.
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.
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
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.
It can’t use motor or generator power for moving purpose so that it helps to
reduce the output cost.
CHAPTER THREE
Need or Aim
( )
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.
v
Personal Mechanical Individual depth interview
interview observation
Companies Human observation
Email Simulation
Case studies
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.
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
Working principle of model 2
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.
Advantage of model 2
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.
Disadvantage of model 2
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
Component of model 3
Boom Handle
Hook Rope
Wheel Pulley
Base frame Coiler
Bolt and nut Gear box
Component of model 4
Extension boom Cable or remove control
Wheel Bolt and nut
Motor
Advantage of model 4
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.
Disadvantage of model 4
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
Component of model 5
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.
Working principle of model 5
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.
Advantage of model 5
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.
Disadvantage of model 5
The structure is exposed to stress and fracture.
6. MODEL-6
Component of model 6
Boom
Trolley
Mast
Gusset
Trapezoidal web
Working principle of model 6
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.
Advantage of model 6
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.
Disadvantage of model 6
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
Component of model 7
Base Pump Lever
Mast Lift cylinder
Metal Roller Hook
Pump Boom
Handle Load locking device
Working principle of model 7
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.
Advantage of model 7
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.
Disadvantage of model 7
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
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
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
3.5. 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.
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.
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
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.
θ1 = 65°
θ2 = 50°
Lb = 1250 mm
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
L2 = 𝟏𝟓𝟐. 𝟐𝟕 𝐦𝐦
L3 = 𝟕𝟗𝟏𝐦𝐦
𝛉𝟑 = 90 − θ4 = 90 − 78.9° = 𝟏𝟏. 𝟏°
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
Now, L = L3 + L4
L4 = L − L3 = 1393.16mm − 791mm = 602.16mm
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
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
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
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)
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
To find shear force at each point take sum of force along y-axis is zero
+↑ 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
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
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
is safe due to bending load when the hydraulic cylinder at extracted position.
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
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))
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.
C1x + C2
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
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
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 = 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
b3 = 8,904033.512mm3
b = 𝟐𝟎𝟕. 𝟐𝟔𝟔𝐦𝐦
b 207.266mm
t = 20 = = 𝟏𝟎. 𝟑𝟔𝟑𝐦𝐦
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 ≥ 207.266mm and t ≥ 10.363mm.
b=250mm,
t=12mm,
h=b-2t=250mm-2*12mm=226mm
Therefore, checking for the safety:
b 250mm
M∗ 95265.414kNmm∗
σb = 2
= 2
= 𝟏𝟏𝟎. 𝟏𝟑𝟒 𝐍⁄
b −h4
4 (250mm) −(226mm)4
4
𝐦𝐦𝟐
12 12
Where
Fx ′ a = 102.975𝑘𝑁
A= area of the cross section of the material=b2 − h2
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
A=area of the cross section of the material=b2 − h2
According the principal stress the following equation can be solving the principal stress.
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
Therefore the maximum shear stress theory is:
1
τmax = 2 (σ1 − σ2) = 1⁄2 (119.826Mpa + 0.678Mpa)
And to find the safety factor use of the maximum distortion energy theory
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
F. s new = 120.504Mpa = 120.504Mpa = 2.324 > 1.5, it is 𝐬𝐚𝐟𝐞!
∴ 𝐝𝐞𝐬𝐢𝐠𝐧 𝐨𝐟 𝐛𝐚𝐜𝐤 𝐡𝐨𝐢𝐬𝐭 𝐛𝐨𝐝𝐲 𝐢𝐬 𝐬𝐚𝐟𝐞 𝐝𝐮𝐞 𝐭𝐨 𝐛𝐞𝐧𝐝𝐢𝐧𝐠 𝐥𝐨𝐚𝐝, 𝐚𝐱𝐢𝐚𝐥 𝐥𝐨𝐚𝐝 𝐚𝐧𝐝 𝐬𝐡𝐞𝐚𝐫 𝐥𝐨𝐚𝐝.
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)
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
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
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
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
4 Timber 50 1⁄
750
∴ 𝐝𝐞𝐬𝐢𝐠𝐧 𝐨𝐟 𝐛𝐚𝐜𝐤 𝐡𝐨𝐢𝐬𝐭 𝐛𝐨𝐝𝐲 𝐢𝐬 𝐬𝐚𝐟𝐞 𝐝𝐮𝐞 𝐭𝐨 𝐜𝐫𝐢𝐩𝐩𝐥𝐢𝐧𝐠 𝐥𝐨𝐚𝐝 𝐨𝐫 𝐛𝐮𝐜𝐤𝐥𝐢𝐧𝐠 𝐥𝐨𝐚𝐝 𝐚𝐧𝐝 𝐜𝐫𝐮𝐬𝐡𝐢𝐧𝐠 𝐥𝐨𝐚𝐝.
Therefore from the above FBD the values of “x” and “y” are
y y
tan 45° = =
m 268.214mm
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
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
To find shear force at each point take sum of force along y-axis is zero
+↑ Σfy = 0, Vx + Fyi = 0
Vx = −Fyi = −50.525kN
Vi@(x1 = 0mm) = VA@(x1 = 468.214mm) = −Fyi = −𝟓𝟎. 𝟓𝟐𝟓𝐤𝐍
Bending moment and shear force at section x2-x2
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
To find shear force at each point take sum of force along y-axis is zero
+↑ 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
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 = 11,828.094kNmm and b=h+2*t, h=b-2*t
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
b3 = 1,105,519.211mm3
b = 𝟏𝟎𝟑. 𝟒𝐦𝐦
b 103.4mm
t = 20 = = 𝟓. 𝟏𝟕𝐦𝐦
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 ≥ 103.4mm and t ≥ 5.17mm.
b=120mm,
t=6mm,
h=b-2t=120mm-2*6mm=108mm
Therefore, checking for the safety:
b 120mm
M∗ 11,828.094kNmm∗
σb = 2
= 2
= 𝟏𝟏𝟗. 𝟒𝟐𝟒 𝐍⁄
b4 −h4 (120mm)4 −(108mm)4 𝐦𝐦𝟐
12 12
Where
Fxi+Fxj Fx′ a∗cos θ4 19.824kN
Faxial = = = = 9.912kN
2 2 2
Where
Vmax = Fyj = 50.525kN
A=area of the cross section of the material=b2 − h2
According the principal stress the following equation can be solving the principal stress.
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
Therefore the maximum shear stress theory is:
1
τmax = 2 (σ1 − σ2) = 1⁄2 (125.759Mpa + 2.712Mpa)
And to find the safety factor use of the maximum distortion energy theory
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
( f.s ) = 16,504.798Mpa2
σy
= 128.471Mpa
F.s
σy 280Mpa
F. s new = 128.471Mpa = 128.471Mpa = 2.18 > 1.5, it is 𝐬𝐚𝐟𝐞!
∴ 𝐝𝐞𝐬𝐢𝐠𝐧 𝐨𝐟 𝐛𝐚𝐬𝐞 𝐛𝐨𝐝𝐲 𝐢𝐬 𝐬𝐚𝐟𝐞 𝐝𝐮𝐞 𝐭𝐨 𝐛𝐞𝐧𝐝𝐢𝐧𝐠 𝐥𝐨𝐚𝐝, 𝐚𝐱𝐢𝐚𝐥 𝐥𝐨𝐚𝐝 𝐚𝐧𝐝 𝐬𝐡𝐞𝐚𝐫 𝐥𝐨𝐚𝐝.
The least radius of gyration of the square hollow section (k) is given by
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
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.
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
From the above table 4.1:3 the value of C is select 4 because of base body is both end
fixed.
using mild steel read from above table 4.1:4,
a=1/7500
σc = 320Mpa
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!
Leh = 1136.377mm
Lh Lh 1108.364
tan θh = Lkk , θh = tan−1[ Lkk ] = tan−1 [ 501.524 ]
( ) ( ) ( )
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
b
M∗
Therefore, σb = 2
b4 −h4
but, M = 47,632.707kNmm and b=h+2*t, h=b-2*t
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
b3 = 4,452,016.756mm3
b = 𝟏𝟔𝟒. 𝟓𝟎𝟕𝐦𝐦
b 164.507mm
t = 20 = = 𝟖. 𝟐𝟐𝟓𝐦𝐦
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 ≥ 164.507mm and t ≥ 8.225mm.
b=175mm,
t=9mm,
h=b-2t=175mm-2*9mm=157mm
Therefore, checking for the safety:
b 175mm
M∗ 47,632.707kNmm ∗
σb = 2
= 2
= 𝟏𝟓𝟏. 𝟒𝟏𝟑 𝐍⁄
b4 −h4 (175mm)4 −(157mm)4 𝐦𝐦𝟐
12 12
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
According the principal stress the following equation can be solving the principal stress.
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
Therefore the maximum shear stress theory is:
1
τmax = 2 (σ1 − σ2) = 1⁄2 (162.979Mpa + 0.042Mpa)
And to find the safety factor use of the maximum distortion energy theory
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
F. s new = 163.021Mpa = 163.021Mpa = 1.718 > 1.5, it is 𝐬𝐚𝐟𝐞!
∴ 𝐝𝐞𝐬𝐢𝐠𝐧 𝐨𝐟 𝐛𝐚𝐜𝐤 𝐡𝐨𝐢𝐬𝐭 𝐬𝐮𝐩𝐩𝐨𝐫𝐭 𝐢𝐬 𝐬𝐚𝐟𝐞 𝐝𝐮𝐞 𝐭𝐨 𝐛𝐞𝐧𝐝𝐢𝐧𝐠 𝐥𝐨𝐚𝐝, 𝐚𝐱𝐢𝐚𝐥 𝐥𝐨𝐚𝐝 𝐚𝐧𝐝 𝐬𝐡𝐞𝐚𝐫 𝐥𝐨𝐚𝐝.
Hence if the slenderness ratio is less than 80, Euler’s formula for a mild steel column is
not valid.
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
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
The least radius of gyration of the square hollow section (k) is given by
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
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.
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
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.
using mild steel read from above table 4.1:4,
a=1/7500
σC =320Mpa
crushing load is given by
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!
crippling load is given by
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
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
Bending moment at section x2-x2
∑ M@x2 = 0, , Fyo ∗ x2 − Fy ′ k ∗ (x2 − 71.788) − Mk + Mx2 = 0
Mx2 = −Fyo ∗ x2 + Fy ′ k ∗ (x2 − 71.788) + Mk
There fore
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
First find reaction force and moment
Force along y-axis from the above figure 4.1:22
+↑ ΣFz = 0
Fzo − Fxi = 0
Fzo = Fxi
Fzo = 9.912kN
Bending moment at section x1-x1
∑ 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
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 = 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
b3 = 4,100,333.309mm3
b = 𝟏𝟔𝟎𝐦𝐦
b 160mm
t = 20 = = 𝟖. 𝟎𝟎𝟑𝐦𝐦
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 ≥ 160mm and t ≥ 8.003mm.
b=175mm,
t=9mm,
h=b-2t=175mm-2*9mm=157mm
Therefore, checking for the safety:
b 175mm
M∗ 43,870kNmm∗
σb = 2
= 2
= 𝟏𝟑𝟗. 𝟒𝟓𝟐 𝐍⁄
b4 −h4 (175mm)4 −(157mm)4 𝐦𝐦𝟐
12 12
Where
Vmax = 52.507kN
A=area of the cross section of the material=b2 − h2
According the principal stress the following equation can be solving the principal stress.
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
Therefore the maximum shear stress theory is:
1
τmax = 2 (σ1 − σ2) = 1⁄2 (140.004Mpa + 0.276Mpa)
And to find the safety factor use of the maximum distortion energy theory
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
F. s new = 140.28Mpa = 140.28Mpa = 1.996 > 1.5, it is 𝐬𝐚𝐟𝐞!
∴ 𝐝𝐞𝐬𝐢𝐠𝐧 𝐨𝐟 𝐡𝐨𝐫𝐢𝐳𝐨𝐧𝐭𝐚𝐥 𝐟𝐫𝐚𝐦𝐞 𝐢𝐬 𝐬𝐚𝐟𝐞 𝐝𝐮𝐞 𝐭𝐨 𝐛𝐞𝐧𝐝𝐢𝐧𝐠 𝐥𝐨𝐚𝐝, 𝐚𝐱𝐢𝐚𝐥 𝐥𝐨𝐚𝐝 𝐚𝐧𝐝 𝐬𝐡𝐞𝐚𝐫 𝐥𝐨𝐚𝐝.
MN
Tensile strength (σt) = 480 m2
MN
Yield strength (σy) = 280 m2
Kg
Density (ρ) = 7800 m3
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
To find shear force at each point take sum of force along y-axis is zero
+↑ Σfy = 0, Vx + Fym = 0
Vx = −Fym = −51.563kN
Vm@(x1=0mm) = Vo@(x1=468.214mm) = −Fym = −𝟓𝟏. 𝟓𝟔𝟑𝐤𝐍
Bending moment and shear force at section x2-x2
Mx = Fym ∗ x2
𝐌𝐦@(x2=0mm) = 51.563kN ∗ 0mm = 𝟎𝐤𝐍𝐦𝐦
𝐌𝐨@(x2=268.214mm) = 51.563kN ∗ 268.214mm = 𝟏𝟑, 𝟖𝟐𝟗. 𝟗𝟏𝟖𝐤𝐍𝐦𝐦
To find shear force at each point take sum of force along y-axis is zero
+↑ 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
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 = 13,829.918kNmm and b=h+2*t, h=b-2*t
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
b3 = 1,292,620.776mm3
b = 𝟏𝟎𝟖. 𝟗𝟑𝟐𝐦𝐦
b 108.932mm
t = 20 = = 𝟓. 𝟒𝟒𝟕𝐦𝐦
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 ≥ 108.932mm and t ≥ 5.447mm.
b=175mm,
t=6mm,
h=b-2t=175mm-2*6mm=163mm
Therefore, checking for the safety:
b 175mm
M∗ 13,829.918kNmm∗
σb = 2
= 2
= 𝟔𝟐. 𝟓𝟗𝟖 𝐍⁄
b4 −h4 (175mm)4 −(163mm)4 𝐦𝐦𝟐
12 12
Where
Vmax = Fym = 51.563kN
A=area of the cross section of the material=b2 − h2
F Fy′A 50.525kN 51.563kN
τ=A= = = 1752 −1632 = 𝟏𝟐. 𝟕𝟏𝟑𝐌𝐩𝐚
A b2 −h2
According the principal stress the following equation can be solving the principal stress.
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
Therefore the maximum shear stress theory is:
1
τmax = 2 (σ1 − σ2) = 1⁄2 (65.082Mpa + 2.484Mpa)
And to find the safety factor use of the maximum distortion energy theory
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
F. s new = 67.566Mpa = 67.566Mpa = 4.144 > 1.5, it is 𝐬𝐚𝐟𝐞!
∴ 𝐝𝐞𝐬𝐢𝐠𝐧 𝐨𝐟 𝐜𝐨𝐧𝐧𝐞𝐜𝐭𝐢𝐧𝐠 𝐟𝐫𝐚𝐦𝐞 𝐢𝐬 𝐬𝐚𝐟𝐞 𝐝𝐮𝐞 𝐭𝐨 𝐛𝐞𝐧𝐝𝐢𝐧𝐠 𝐥𝐨𝐚𝐝, 𝐚𝐱𝐢𝐚𝐥 𝐥𝐨𝐚𝐝 𝐚𝐧𝐝 𝐬𝐡𝐞𝐚𝐫 𝐥𝐨𝐚𝐝.
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
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
h 41.402mm 41.402𝑚𝑚
Rn = R = 66.802mm = = 42.815𝑚𝑚
log𝑒 ( o ) log𝑒(
25.4mm
) 0.967
Ri
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)
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
According the principal stress the following equation can be solving the principal stress.
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
Therefore the maximum shear stress theory is:
1
τmax = 2 (σ1 − σ2) = 1⁄2 (246.081Mpa + 3.289Mpa)
And to find the safety factor use of the maximum distortion energy theory
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.
4.4.9.1.1. 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
Therefore
Fxc∗L 218.959kN∗250mm
Mxzmax@c = = = 13,684.938kNmm
4 4
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
32∗26,096.923kNmm
= 626.667 N⁄mm2
πd3
d3 = 424,182.341mm3
𝐝 = 𝟕𝟓. 𝟏𝟑𝟔𝐦𝐦
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
32∗M 32∗26,096.923kNmm
σb = = = 519.182Mpa
πd3 π(80mm)3
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
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
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
Therefore
W∗L 29.43kN∗80mm
Mmax@c = = = 588.6kNmm
4 4
32∗588.6kNmm
= 626.667 N⁄mm2
πd3
d3 = 9,567.171mm3
𝐝 = 𝟐𝟏. 𝟐𝟐𝟗𝐦𝐦
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
32∗M 32∗588.6kNmm
σb = = = 128.503Mpa
πd3 π(36mm)3
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
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
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
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
Front wheel:
Material selection for front wheel is Steel-ductile
From the above total load of the machine the load carrying capacity of connecting frame,
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
Rare Wheels:
Material selection for rare wheel is steel –Ductile plate swivel
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.
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.
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.
(1) Square butt joint, (2) Single-V preparation joint, (3) Lap joint, (4) T-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.
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.
Facing Lath
Welding Electric arc
Painting Painting machine
Casting Sand mold
CHATER FIVE
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
frame steel
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]
∈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
∈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
∈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) ($)
($/kg) (m) (m)
Horizontal Mild 1 2.6 7800 0.203 0.184 1.25 0.009191 71.6917 186.399
Boom steel 5
Back hoist Mild 1 2.6 7800 0.25 0.226 1.3932 0.015915 124.140 322.766
steel 5
Base body Mild 1 2.6 7800 0.12 0.108 0.9364 0.002562 19.984 51.958
steel
Back hoist Mild 2 2.6 7800 0.175 0.157 1.1364 0.01358 105.939 275.441
support steel
Horizontal Mild 2 2.6 7800 0.175 0.157 1.7678 0.02113 164.794 428.464
frame steel
Connectin Mild 1 2.6 7800 0.175 0.163 0.9364 0.003798 29.6255 77.025
g frame steel
Where
b= base of each material
h= height of each material
L=length of each material
D= diameter of each material
Qty= quantity of each material
ρ =density of each material
U=($/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
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
6.4. 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
7.1. 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.
[4] Coulton, J. J. (1974), "Lifting in Early Greek Architecture", The Journal of Hellenic
Studies, 94: 1–19, doi:10.2307/630416,JSTOR 630416, pp.14f.
[5] Coulton, J. J. (1974), "Lifting in Early Greek Architecture", The Journal of Hellenic
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”.
[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.
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.
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
(mild
steel)
[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]
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)
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
[Source: www.consteel.com.sg]
Table 0:4.A. specification for steeled in millimeter series screws and bolts
Table 0:5.A. Basic dimensions for square threads in mm (Normal series) according to IS: 4694 –
1968 (Reaffirmed 1996)
Normal series
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
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
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]
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Material
Bounding Box
Length X 0.203 m
Length Y 0.203 m
Properties
Centroid X -2.2476e-002 m
Centroid Y 7.6148e-002 m
Statistics
Scope
Definition
Suppressed No
Define By Components
X Component 0. N (ramped)
Table 0:7.A. Input Data for Ansys results of back hoist body
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Material
Bounding Box
Length X 0.25 m
Length Z 0.25 m
Properties
Centroid X -2.2263e-002 m
Centroid Z 0.27639 m
Statistics
Scope
Scoping
Geometry Selection
Method
Geometry 1 Edge
Definition
Suppressed No
Coordinate
Global Coordinate System
System
X Component 0. N (ramped)
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
Table 0:8.A. Input Data for Ansys results of back hoist body
Model (A4) > Geometry > Parts
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 X -1.6981e-003 m
Centroid Y 2.5643e-002 m
Centroid Z -1.9431e-002 m
Statistics
Nodes 2041
Elements 999
Scope
Definition
Suppressed No
Define By Components
X Component 0. N (ramped)
Z Component 0. N (ramped)