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Sainath Karpe2,
Ajaykumar Chawrai3
Ajinkyakarpe97@gmail.com sainathkarpe14@gmail.com
ajaypchawrai@gmail.com
1, 2, 3 (Undergraduate Student, Department of Mechanical Engineering, Sardar Patel College of Engineering, Mumbai 400058)
Abstract Tower cranes are used at construction site. Tower crane jib is suspended beam which carries load moving
along the jib. While designing components need to design crane hook & snatch block assembly, wire ropes, moving
trolley, tie rods, jib, counterweight side, mast, slewing ring. We selected jib for analysis since we wanted to validate the
use of ANSYS (FEM method) for structural design of Tower Crane Jib. Jib model was generated in ANSYS 14.5
workbench and further analyzed in the same. Two models of Tower Crane jib were compared initially for axial force
and deformation developed in members of the jib and the better model was selected for further analysis. Throughout
the analysis, the load has been applied at the end of the jib of the tower crane to generate maximum moment and
stresses in the jib. Initially the results of ANSYS 14.5 were validated using analytical method for the jib (Method of
sections for trusses). Later, the results for static as well as dynamic analysis are obtained. In static analysis, cranes
self weight, payload, hook weight, trolley weight and wind loading are considered whereas acceleration, braking, and
angular velocity are considered in dynamic analysis,.
Keywords Tower Crane, Jib, Tie Rod, Aerodynamic Coefficient, Counterweight, FEM, Method of Sections.
1. INTRODUCTION
Cranes are widely used to transport heavy loads and hazardous materials in shipyards, factories, nuclear installations, and
high-building construction and play an important role in production process and serve to transfer loads from one place to
another. Cranes are the best way of providing a heavy lifting facility covering virtually the whole area of the industry.
Their design features vary widely according to their major operational specifications such as the type of motion, dead
weights and type of the load, location of the crane, geometric features and environmental conditions. Since the crane
design procedure is highly standardized with critical components, main effort and time spent mostly for interpretation
and implementation of available design standards. A tower crane is a type of crane with a hoist in a trolley which runs
horizontally along gantry rails, usually fitted underneath a beam spanning between uprights which themselves have
wheels so that the whole crane can move at right angles to the direction of the gantry rails. [9]
Tower cranes are a modern form of balance crane that consist of the same basic parts. Fixed to the ground on a concrete
slab (and sometimes attached to the sides of structures as well), tower cranes often give the best combination of height
and lifting capacity and are used in the construction of tall buildings. The base is then attached to the mast which gives
the crane its height. Further the mast is attached to the slewing unit (gear and motor) that allows the crane to rotate. On
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top of the slewing unit there are three main parts which are: the long horizontal jib (working arm), shorter counter-jib,
and the operator's cab. The long horizontal jib is the part of the crane that carries the load. The counter-jib carries a
counterweight, usually of concrete blocks, while the jib suspends the load to and from the center of the crane. The crane
operator either sits in a cab at the top of the tower or controls the crane by radio remote control from the ground. In the
first case the operator's cab is most usually located at the top of the tower attached to the turntable, but can be mounted
on the jib, or partway down the tower. The lifting hook is operated by the crane operator using electric motors to
manipulate wire rope cables through a system of sheaves. The hook is located on the long horizontal arm to lift the load
which also contains its motor. [10]
2.
From ANSYS analysis, Type-1 gives deformation of 24.04mm and maximum axial member forces of 119.87KN
Type-2 generates deformation of 18.29mm and maximum axial member force of 102.78 KN
Hence type-2 (Triangular type) is selected for application.
3. TOWER CRANE SPECIFICATIONS
Tower crane specifications: [3]
1. Hoisting
19m/min for max load 16 ton
2. Trolleying Speed
69m/min
3. Slewing
0.8 rpm
4. Tower Crane height 90m
5. Jib Acceleration
0 to 0.8 rpm in 30 seconds
6. Material
ST 63
7. Max. capacity at the end of jib 2 tons
8. Radius of tower crane 78m
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1.
2.
3.
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The top member of the jib was kept circular since it undergoes tensile loads.
The bottom members of the jib were kept I sections since I sections have better resistance against buckling
failure.
The side members were made up of L section since they have good strength against bucking and bending (due to
wind loading)
5.
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6. RESULT TABLE
Members
Area
10^(-3)
m^2
ANSYS
Analytical
Stress
MPa)
63.78
(in
Stress
(in MPa)
59.88
% error
T1
5.026
T2/2
5.026
194.76
38.75
201.029
39.99
3.1
R1
2.827
298.05
105.41
299.228
105.83
.4
R2/2
3.272
154.17
47.11
162.83
49.76
5.3
R3/2
0.186
18.641
107.52
18.44
99.16
7.9
R4/2
0.186
16.047
86
22.23
118
27.11
R5
0.186
0.632
3.397
0.640
3.44
1.25
The above table shows that the ANSYS results are validated and hence it can be used for further analysis
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7. STATIC ANALYSIS:
Forces applied:
1. Self weight
2. Live Load (at the end of the jib 2 tons)
3. Wind Load
Wind loading calculations:
Section 1: Wind loading calculations on L section of Jib (considering perpendicular wind direction) (length= 3.87 m)
Force due wind, F = A p Cf [2]
where, p = 0.613Vs210-3 ( KPa )
Vs = 20 m/s (wind velocity) [6]
Projected area of L section, A= 0.18m2
p= 0.61320210-3
p= 245.2 Pa
Cf = 1.9 [2] (shape factor based upon aerodynamic drag coefficient for L section)
Substituting these values in above force equation,
F = 84 N
This 84N force acts on one L section member.
Section 2: Wind loading calculations on I section of Jib
(length = 3m )
Force due wind, F = A p Cf [2]
p = 0.613Vs210-3 ( KPa )
Vs = 20 m/s [6]
Projected area of L section, A= 0.69m2
p= 0.61320210-3
p= 245.2 Pa
Cf = 1.6 [2] (shape factor based upon aerodynamic drag coefficient for I section)
Substituting these values in above force equation,
F = 270 N
This 270N force acts on one I section member.
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8. DYNAMIC ANALYSIS:
Forces Applied:
1.
2.
3.
Static Forces
Angular Velocity (0.8 rpm)
Acceleration Load (0 to 0.8 rpm in 30 sec)
The jib was analysed for acceleration only since the braking force applied was assumed equal to the acceleration force
applied. The forces on each member were distributed on the respective nodes.
Calculations for tangential acceleration and centripetal force:
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9.
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RESULTS:
STATIC ANALYSIS:
Maximum Stress induced: 99.6 MPa
F.O.S: 355/99.6 = 3.56
DYNAMIC ANALYSIS:
Maximum Stress induced: 229.69 MPa
F.O.S: 355/229.69 = 1.54
10. CONCLUSION:
1.
2.
3.
Wind loading was observed to be major criteria in the design of structure for the Tower Crane.
As the computed stress values in the jib are smaller than the allowable stress of Material (Structural Steel) of the
components, it is observed that the jib crane is safe according to I.S norms [6]. The analytical and FEA (ANSYS)
results are very close. The results obtained from FEA analysis show that the boundary conditions have been
chosen correctly.
Use of FEM method for structural analysis of Tower Crane Jib is validated and hence a lot of computing time
can be saved for the calculation of jib forces.
REFERENCES:
[1]
[2]
[3]
[4]
[5]
[6]
[7]
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