STRUCTURAL ANALYSIS TO IMPROVE THE PERFORMANCE OF A

RETRACTABLE JOINTED-CRANE: FAILURE DUE TO OVERLOADING

Víctor Alfonso Ramírez-Elías1, Antonio de Jesús Balvantín-García2, Alberto Saldaña-Robles3, Kyosung Choo4,
José Angel Diosdado-De la Peña5

ABSTRACT

This paper proposes a numerical assessment of the after-test failure of a retractable jointed-crane
by using finite element analysis (FEA). The original design of the equipment involves a jointed
section of coplanar arms and a telescopic section of collinear arms, which complies with the
prevalent design standard, applicable for this kind of machinery in Mexico. A prototype of this
design was built and was damaged during a beta test, presumably due to a crane misuse. The
suggested numerical analysis was carried out in a FEA commercial software by assembling the
component by kinematic pairs method, and considering dynamic loads and their resulting reactions
at each element. The numerically obtained failure in the components was compared with the observed
damage which indicated a difference less than ten percent in the permanent deformation results.
Some modifications are recommended on the damaged components to increase the minimum safety
factor, reaching up to sixty percent increment in this performance parameter. The causes of the
failure are discussed based on the numerical results, and operation recommendations are argued
in order to avoid future complications.

Keywords: lifting crane; finite element analysis; failure analysis; structural redesign; computer
aided engineering; dynamic loads.

1. INTRODUCTION

Crane design is usually carried out according to the experience of the manufacturer or by reverse
engineering applied on existing designs [1, 2]. In order to avoid inconveniences such as non-scheduled

1 Associate Professor, Department of Mechanical Engineering, University of Guanajuato, Mexico, Ph. +52 (464) 6479940×2366,
Email: va.ramirez@ugto.mx.
2 Associate Professor, Department of Mechanical Engineering, University of Guanajuato, Mexico, Ph. +52 (464) 6479940×2363,
Email: antonio.balvantin@ugto.mx.
3 Professor, Department of Mechanical Agricultural Engineering, University of Guanajuato, Mexico, Ph. +52 (462) 6241889×5227,
Email: alberto.saldana@ugto.mx.
4 Associate professor, Department of Mechanical, Industrial and Manufacturing Engineering, Youngstown State University, USA,
Ph. +1 (330) 9413030, Email: kchoo@ysu.edu.
5 Graduate Student, Department of Mechanical, Industrial and Manufacturing Engineering, Youngstown State University, USA,
Ph. +1 (330) 5092647, Email: jdiosdadodelapen@student.ysu.edu.

Manuscript received on 24th November 2021, reviewed and accepted on 2nd April 2022 as per publication
policies of NED University Journal of Research. All rights are reserved in favour of NED University of
Engineering and Technology, Karachi, Pakistan. Pertinent discussion including authors’ closure will be
published in July 2023 issue of the Journal if the discussion is received by 31st January 2023.
NED UNIVERSITY JOURNAL OF RESEARCH - STRUCTURAL MECHANICS, VOL XIX, NO. 3, 2022
https://doi.org/10.35453/NEDJR-STMECH-2021-0009 37
 V. Ramirez et al.

Victor Ramirez is an Associate Professor at University of Guanajuato, México where he obtained

his Bachelors and Masters in 2007 and 2010, respectively. He obtained his PhD in composite
materials from the University of Manchester, UK in 2015 where he worked a postdoctoral
researcher in 2017. His research interests include structural analysis and composite materials.

Antonio Balvantín is an Associate Professor in the Department of Mechanical Engineering, University

of Guanajuato, México. He obtained his Masters and PhD in robotics and advanced manufacturing
from National Polytechnic Institute, Mexico in 2009 and 2014, respectively. His research interests
include quantitative nondestructive evaluation of materials, mechanical design, mechanics of
interfaces, and development of automatic and robotic systems for nondestructive quality control.

Alberto Saldaña-Robles is an Associate Professor in the Department of Agricultural Engineering

at the University of Guanajuato, Irapuato, México where he received his PhD in mechanical
engineering in 2016. His research interests include mechanical design, manufacturing and
finishing processes, numerical simulation, and additive manufacturing.

Kyosung Choo is an Associate Professor of mechanical engineering at Youngstown State University,

USA. He received his Masters and PhD in mechanical engineering from Korea Advanced Instituted
of Science and Technology, Korea. He is an author of more than 40 articles and technical papers.
His research interests include heat transfer for additive and advanced manufacturing, two-phase
flow, jet impingement, energy efficiency of data centers and buildings, and electronics cooling.

José Angel Diosdado-De-la-Peña is a PhD student in materials science and engineering at

Youngstown State University, USA. He obtained in Bachelors, Masters and PhD from the
University of Guanajuato, Mexico in 2006, 2008 and 2013, respectively. His research interests
include modelling manufacturing process, physical phenomena, and product development via
finite element method.

service of the crane or lack of information regarding its structural performance to any applicable
standard [3, 4], various support technologies and analysis methods have been adopted in the
development process of this type of equipment.

Among the methods commonly used for the analysis of the crane constituent components, the
synthesis of kinematics and its solution through numerical methods [5-9], and the analytical models
for optimisation [10, 11] are worth mentioning. However, the most widely used technologies include
computer-aided design (CAD) and engineering software (CAE), which are used for three-dimensional
modelling of a geometry [12, 13] and its subsequent simulation under different working conditions
[14]. Some of these programs use finite element method (FEM) to synthesize the constituent
components and to assess their behaviour under a variety of applied loads and conditions [15].

Commercial FE Analysis (FEA) software have been used to study different types of equipment with
diverse applications such as workshops [13, 16], marine platform [5, 21] and construction features
as tower cranes [1 ,9, 17-20], caterpillar cranes [14, 15], telescopic cranes [6, 7, 22, 23], bridge
cranes [10-12, 24-26], and jointed cranes [8] to name a few. In most of these studies, static analysis
has been carried out to determine the mechanical performance of the equipment under live and dead
loads [1, 10, 12, 14, 16, 18, 21-23, 25]. Additionally, a variety of analyses include inertial effects
in a static analysis via a dynamic load factor [21] or through explicit dynamic loads [18, 22]. Han
et al. [21] performed coupled field analysis in order to add the effect of wind on a structure of a
marine platform crane. Other authors focused their work on the behaviour of the structure under
cyclic loads such as mechanical vibrations, through modal and harmonic analyses [17, 20, 24, 26].
FEA validation is regularly carried out by comparing the numerical results with the analytical data,
and strain gauge experimental data [18, 23-25]. Such comparison is considered satisfactory if an
error factor smaller than five percent is obtained, at least for static loads with experimental data [23].
38 NED UNIVERSITY JOURNAL OF RESEARCH - STRUCTURAL MECHANICS, VOL XIX, NO. 3, 2022
Nevertheless, a model with dynamic loads is more trustworthy for the simulation of failure conditions,
even when its numerical-experimental correlation might lead to a higher error [22].

Both dynamic and structural analysis through FEM were used to analyse the failure of a prototype
crane during a beta trial in this paper. The design of this crane consists of a jointed section with
coplanar arms and a telescopic section with collinear arms [27], that fulfils ANSI/SAIA 92.2-2015
standard [4] for aero devices of elevation and rotation assembled on vehicles. This standard requires
a design stress not exceeding fifty percent of the minimum yield strength for ductile materials so as
to provide a minimum safety factor (MSF) of 2.0. The prototype was built by a hydraulic equipment
company (located and with distribution in Mexico) reaching a maximum height of 13.0 m (43 ft.),
a maximum horizontal length of 6.5 m (21 ft.), capable to carry the equivalent weight of two workers
with tools (approximately 2,158 N (485 lb)) and is mounted on a motor vehicle (Figure 1(a)). During
a beta trial, this prototype was used by one of the manufacturer’s customers to lift a utility pole (3,031
N (681 lb)), a loading condition neither considered by the standard nor during the design stage. It
is suspected that this unexpected operation condition damaged the rotational base of the prototype
(Figure 1(b)) as well as the union bolt, since both distorted elements were visible once the crane was
disassembled after the beta trial. The failure of the union bolt (38.1 mm (1.5 in.) in diameter) was a
permanent deformation of approximately 3.4 mm (0.13 in.), due to high stress concentration causing
yielding as shown in Figure 1(c). Both parts of the crane (the rotational base and the union bolt)
were machined and assembled by the manufacturer, along with other constituent components.

(a)

Figure 1. Crane prototype: (a) during initial testing with collinear arms extended with
a list of its main constituent components, before beta trial; (b) damage on side plate in
the rotational base, after the beta trial; (c) union bolt permanent deformation (3.4 mm
(0.13 in.)) after the beta trial.
NED UNIVERSITY JOURNAL OF RESEARCH - STRUCTURAL MECHANICS, VOL XIX, NO. 3, 2022 39
 V. Ramirez et al.

(b) (c)

Figure 1. Continued.

Finite element models were used to analyse the movements of the crane prototype in this paper,
considering lifting of the utility pole and its effects on the constituent components during the elevation.
Therefore, dynamic loads were considered. The reference parameter for mechanical performance of
the component is MSF, as set by ANSI/SAIA 92.2-2015 standard [4]. Based on the structural analyses,
a failure prediction in the rotational base was numerically obtained and compared with the observed
damage. The forthcoming section provides a description of the materials and methodology used herein.

According to the appropriated reproduction of the observed damage with the numerical results in
this work, the methodology used will serve to predict possible failures in later designs of this type
of cranes. Therefore, it provides the manufacturer the means for saving time and resources, (but
above all) avoiding a possible failure in operation, which would have serious consequences on the
physical integrity of users.

2. MATERIALS AND METHODS

2.1 Materials

Standard materials used for the construction of this mechanism were considered in the modelling
procedure. Particularly, numerical structural analysis of the components by FEM requires elastic
modulus (E), Poisson´s ratio (n) and density (r) of material. Since the prototype was manufactured
completely with steel, typical values of E, n and r were taken as 200 GPa (29×106 psi), 0.26 and
7850 kg/m3 (490 lb/ft3), respectively. These values are common for the different kinds of steels,
such as ASTM A36 and AISI 1018 CD. The above material property data and other mechanical
properties were provided by the material supplier [28] and consulted on specialized websites [29].

2.2 Methods

The methodology followed in this paper involved CAD modelling and FEA of the crane to obtain
the distribution of the loads and reactions along different components.

2.2.1Computer-aided design modelling

The geometry of the crane was modelled using a commercial CAD software entitled CATIA V5®.
Nevertheless, this work does not include the analysis of commercially available components (such
as the basket, bearing and cylinders), as these are acquired from a third party and are selected based
on catalogue specifications.
40 NED UNIVERSITY JOURNAL OF RESEARCH - STRUCTURAL MECHANICS, VOL XIX, NO. 3, 2022
2.2.2Dynamic loads

With the purpose of determining dynamic loads, the model of the crane was imported into ANSYS®
Design Modeler which is a CAD module of this FEA software. In this module, every constituent
component (except for the union bolts) was converted into surfaces with their respective thickness
of profiles and plates while maintaining the geometrical shapes. These modified components were
reassembled using the assembly method of kinematic pairs, to obtain graphical and tabular descriptions
of the evolution of loads as a function of time at every joint of the crane. The first stage of this work
consists of a static analysis of the base supporting the basket, where the weight of utility pole (3031
N (681 lb)) was considered, in order to transfer this load to the crane upper segment.

The dynamic analysis was carried out in ANSYS® Rigid Dynamics module, where every structural
component is considered as a rigid body. Here, the reaction loads at the base of the basket determine
the loads applied at the top of the crane, as shown in Figure 2(a). The purpose of the dynamic
analysis is to determine how the applied loads are transferred as reaction loads at the joints of the
constituent components and the effects due to the elevation process, as performed in the prototype
development process [27]. This analysis indicated that the piston rod from the elevation cylinder
is totally extended in around 13 sec, whereas the piston rod from the folding cylinder is extended
in around 12 sec. Hence, it is estimated that the crane would elevate entirely in about 25 sec, as
required by the manufacturer.

Figure 2(b) shows the reaction momentum on the bottom of the rotational base at the beginning
of the elevation of the mechanism. As shown in Figures 2(c) and 2(d), this momentum reaction
varies as time increases and the crane reaches its maximum vertical elevation. Finally, Figure 2(e)
shows the evolution of the reaction at each previously defined time moment. Once the joint reactions
are determined, loads and momentums can be assigned to the rotational base model, as discussed
in the forthcoming section.

2.2.3Finite element model

As previously mentioned, the rotational base was simulated with a set of surfaces which were
modelled by using shell elements, in ANSYS® Mechanical module. On the other hand, the union
bolt was meshed with solid hexahedral elements and connected to the rotational base through contact
elements. Figure 3 shows FE model of the rotational base and the union bolt assembly, considering
the loads transferred from other constituent components throw the joints. This section of the crane
was manufactured with ASTM A36 steel plates of varying thickness, while the union bolt was
machined with AISI 1018 CD steel. Both steel types considered the same materials properties
mentioned above. Also, the used materials models were considered as bilinear isotropic, with the
complementary mechanical properties described in Table 1.

3 RESULTS AND DISCUSSION

As discussed in the last section of this paper, the safety factors are considered just for the rotational
base and the union bolt. These factors were obtained by von Mises Criterion, also known as distortion
energy theory, used by the ANSYS 15® software.
NED UNIVERSITY JOURNAL OF RESEARCH - STRUCTURAL MECHANICS, VOL XIX, NO. 3, 2022 41
 V. Ramirez et al.

Figure 2. Loads and reactions: (a) used loads ((A) weight, (B-E) loads transferred from
the basket to the base), (F-G) displacements in the folding cylinder and in the elevation
cylinder; (b) reactions at the initial position; (c) reactions at maximum horizontal reach;
(d) reactions at maximum vertical elevation; (e) load as function of simulation time.
42 NED UNIVERSITY JOURNAL OF RESEARCH - STRUCTURAL MECHANICS, VOL XIX, NO. 3, 2022
Figure 3. Finite element model with respective loads at joints of the rotational base,
including union bolt.

Table 1. Properties of steels used in rotational base and union bolt [28-30]
Material Yield strength (SY) Tangent modulus (Et)
MPa (psi) MPa (psi)
ASTM A36 250 (36×103) 1450 (210×103)
AISI 1018 CD 370 (54×103) 1500 (218×103)

3.1 Original Design

MSF were obtained for each constituent component of the original design according to the transferred
loads. Figures 4(a) and 4(b) show the MSF results for the rotational base and the union bolt which
indicate yield failure of the mechanism, as both these are less than 1.0. The union bolt has a smaller
MSF (0.78) compared to the rotational base (0.89), indicating that the union bolt fails first, and its
flaw may lead to the failure of the base. The difference between the observed deformation of the
union bolt (3.4 mm (0.13 in.) in Figure 1(c)) and the results of the FE model (3.07 mm (0.12 in.)
from Figure 4(c)) is approximately 9.7 percent. The low discrepancy value indicates a properly
adjusted FE model. Based on the fact that the damage of these components was reproduced with
the described models, it is reasonable to accept the initial assumption that the overloading by lifting
a utility pole (3031 N (681 lb)) harmed the crane prototype. Although the analysed loading condition
is not recommended and the original design of the crane satisfies the standard requirements, a
redesign of the aforementioned components is proposed in the next section.

3.2 Redesign of Components

In order to increase the calculated MSF of the constituent components (which failed due to the
utility pole lifting), various strategies for structural modifications were considered. The first strategy
involves increasing the thickness of the components; the second one is based on adding reinforcements;
and the final is by changing the material of the components. In order to achieve a satisfactory MSF
value, multiple simulations (implementing the proposed redesigns) were performed. Figure 5(a)
shows the proposed modifications to the rotational base design in order to increase its MSF, these
modifications arise from the analysis of the results of the performed simulations and include a
double thickness back plate (19.0 mm (0.75 in.) thick ASTM A36 steel), reinforcement plate strips
under the bolt bearing (25.4 mm (1 in.) thick ASTM A36 steel) and reinforcements plates bounded
NED UNIVERSITY JOURNAL OF RESEARCH - STRUCTURAL MECHANICS, VOL XIX, NO. 3, 2022 43
 V. Ramirez et al.

Figure 4. Finite element results MSF over the time simulation for lifting the utility pole:
(a) on rotational base; (b) on union bolt; (c) permanent deformation of the union bolt
after lifting the utility pole (mm).

to the side plates (12.7 mm (0.5 in.) thick ASTM A36 steel). For the union bolt a material change
was considered, from AISI 1018 CD to tempered AISI 4140 which increase minimum yield strength
from 370 MPa (53665 psi) to 1100 MPa (160000 psi).

Based on the above described modifications, a new FE model to evaluate the new design of the
rotational base and union bolt was built. This new model includes similar modelling parameters (such
as the element type, materials models and properties and loads) as those used in the original design.
The results of this new FE model are shown in Figures 5(b) and 5(c) which show that MSF increased
to 1.20 and 1.26 for the rotational base and the union bolt, respectively. From this result, it is clear
that the proposed changes improve the performance of the components and the modelling strategies
implemented in this work can be used as a valuable tool in the product optimisation process.
44 NED UNIVERSITY JOURNAL OF RESEARCH - STRUCTURAL MECHANICS, VOL XIX, NO. 3, 2022
Figure 5. Modifications and evaluation: (a) rotational base proposal and MSF over the
time simulation for lifting the utility pole; (b) the rotational base; (c) union bolt.

4 CONCLUSIONS

This paper has analysed a crane design for lifting of personnel which combines jointed and telescopic
sections configurations. The original design of the mechanism satisfies the prevalent design standard.
Nonetheless, two components (rotational base and union bolt) were damaged during a beta trial of
the crane prototype under non-recommended conditions. It is suspected that the damage was caused
by improper loading condition while lifting a 3031 N (681 lb) utility pole.

In order to analyse the failure of the crane, numerical analyses were performed involving dynamic
and inertial loads while lifting the weight of the utility pole. On this basis, the loads transferred from
the top of the crane prototype to the rotational base and the union bolt were obtained. A finite element
model considering both components was built. This model accurately reproduced the damage on
the union bolt with a difference less than ten percent in the remaining deformation. It confirmed
that the observed damage in the components was due to the lifting of the utility pole and was not
a result of any error in the original crane design.

Since the aforementioned loading condition is not considered in the standard applied, usage of this
crane design for an application other that elevating personnel is highly discouraged by the manufacturer.
Nevertheless, on the basis of results from the analysis, some modifications are proposed on the components
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 V. Ramirez et al.
in order to increase its MSF for this loading condition. The proposed modifications are mainly
reinforcements in the rotational base and a material change in the union bolt which increase MSF
from 0.89 and 0.78 to 1.20 and 1.26, respectively.

It was demonstrated that the modelling and analysis methodologies carried out in this paper allowed
to implement changes in the design of the crane, which improved MSF up to sixty percent. This
indicates that they can be used to study new modifications to obtain an MSF value of 2.0 set in the
standard, even for loading conditions not considered originally.

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