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6.1
In this section, we will calculate the hoop stress not only for the pulling load but also
for the braking load for the 1st layer of rope on the drum body due to the compressive
stress. Also, the pressure occurred when a loaded rope is wound onto a winch drum,
wrap by wrap; each successive wraps compress the drum in its area of contact (Refer
to section 3.4). Afterward, we will compare the hoop stress between design codes and
calculated results for both of the loading conditions.
6.2
According to the experimental results, the loaded rope tension throughout the winch
operation is decreasing from far end to near end of the drum whether there is a pulling
load or braking load applied on the drum. As a result, it is shown that the assumption
of uniform tension along the loaded rope is not supported by our experimental results.
Thus, the calculation of hoop stress in this section will be used with decreasing
pressure that acting on the drum by the rope tension due to the pulling or braking load
(Figure 6.1).
As discussed in section 3.4.3 and 3.5, the Hampes solution method gives more
realistic data to get an improve design. Moreover, one of the advantages of this
solution has provided a calculation on each and every wraps continuously onto the
47
winch drum; which we can observe the deflection as well as hoop stress occurring in
each positions under the respective warps on the winch drum in pulling or braking
load conditions.
As mentioned in the Chapter 3, our analysis is based on one particular design of the
winch, which is currently being used, with the following design parameters:
Drum diameter
1000 mm
Drum Length
1775 mm
Drum thickness
70 mm
65 mm
200 tons
1.96 MN
300 tons
2.94 MN
520 MPa
The general formula based on the Hampes solution [9], the hoop stress, h is:
h =
N E
E
= w p ( ) + S1 F7 ( ) + S 2 F15 ( ) + S 3 F16 ( ) + S 4 F8 ( ) ] = [w]
t
R
R
(6.1)
The derivation of the above equation and the various terms are discussed in Appendix
A.
48
w = w p ( ) + S1 F7 ( ) + S 2 F15 ( ) + S 3 F16 ( ) + S 4 F8 ( )
(6.2)
P R2
Et
(1 )
(6.3)
x
,
L
(6.4)
According to the above formulae, account is taken for the decreasing pressure applied
to the drum as illustrated in Figure 6.1.
=0.25
Pressure (P)
=0.75
=1
=0
y=0.5
Drum
Near end
Drum thickness = t
R
D
Far end
Rope
Wraps
Load
49
6.3
For a pulling load of 200 tons and drum thickness of 70 mm, the hoop stress exerts
onto the drum due to the load at each respective positions with the number of wraps
on the drum is as shown in Figure 6.2. According to our calculated results, the highest
hoop stress occurs when the applied load is at =0.8 from the near end of the drum
due to the pulling load. The details calculation of maximum hoop stress is as shown in
Appendix A. However, the highest hoop stress caused by uniform pressure has a
magnitude of 429 MPa according to Table 3.2 method III as drawn in dashed line. So
that, the percentage difference of highest hoop stress between the design codes and
our results is 19%.
Therefore, it can be accomplished that the highest hoop stress, what we called a worse
case scenario, occurs at =0.8 from the near end of the drum and has a magnitude of
348.4 MPa. As a result, we can reduce certain amount of required drum thickness
compared to the design codes.
Hoop stress on the drum after pulling load applied at respective position
0
Const
-90
S tres s in M P a
=0
-180
=0.25
=0.5
-270
=0.8
-360
=1
-450
1
13
Wraps
17
22
27
Fig 6.2 Hoop stress at each respective positions on the drum applied by pulling load
50
6.4
For a braking load of 300 tons and drum thickness of 70 mm, the hoop stress exerts
onto the drum due to the load at each respective positions with the number of wraps
on the drum is as shown in Figure 6.3. According to our calculated results, the highest
hoop stress occurs again at =0.8 from the near end of the drum due to the braking
load. The details calculation of maximum hoop stress is as shown in Appendix A.
However, the highest hoop stress caused by uniform pressure has a magnitude of 643
MPa according to Table 3.2, method III as drawn in dashed line. This design codes
maximum hoop stress is higher than the permissible stress level. However, our
calculated maximum hoop stress is within the permissible level. Also, the percentage
difference of highest hoop stress between the design codes and our results is 42%.
Therefore, it can be accomplished that the highest hoop stress, what we called a worse
case scenario, caused by decreasing pressure occurs again at =0.8 from the near end
of the drum, whether the braking load is at that point or not and has a magnitude of
370.7 MPa. As a result, we can also reduce the certain amount of required drum
thickness compared to the design codes.
51
Const
Stress (MPa)
-200
=0
-300
=0.25
-400
=0.5
-500
=0.8
-600
=1
-700
1
13
Wraps
17
22
27
Fig 6.3 Hoop stress at each respective positions on the drum applied by
braking load
52
6.5
The main difference between these two process is the winding the rope on the drum.
In the coiling (pulling) load process, the loaded rope is wound onto a winch drum in
wrap by wrap starting from the near end to the desire position. Also, each successive
wraps compress by radial pressure inwards on to the winch drum. As for the braking
load, the unloaded rope was wound on the drum from the near end to the desired
position before the load was being applied; unlike the process of coiling the loaded
rope has been done on the drum. The comparison of loading type between these two
applications can be clearly seen on the Figure 6.4 as below.
Fig 6.4 Comparison of braking and pulling load in actual winch operation
Even though these two processes are different, the maximum hoop stress occurs in the
same position, which is =0.8 from the near end of the winch drum. In addition, the
magnitude of maximum hoop stress in pulling and braking load application at =0.8 is
348.4 MPa and 370.7 MPa, respectively.
53
In addition, Table 6.1 shows the comparison of maximum hoop stress at each
respective position between them. These calculated hoop stress will use to compute
required design.
Table 6.1 Maximum hoop stress at respective position for both applications
=0
=0.25
110.4
141.8
=0.5
220
242
=0.8
348.4
370.7
=1
335.7
345.6
As can be seen in the above Table 6.1, although the load applications and magnitude
of load for each operations between the pulling load and braking load is different, the
maximum hoop stress occurs at the same position of around third quarter (=0.8) from
the near end of the drum. In addition, our calculated maximum hoop stress between
pulling load and barking are comparable as the different in percentage is only a 5%;
the weight of braking load should be 1.5 times or less heavily than the weight of
pulling loads.
54
6.6
According to the literature survey and our calculations, the DNV design guide gives
more realistic, more suitable and more easier to compute the required design of winch
drum, even though their formula are quite similar with SAA design guide. The only
difference between these two design guides is the assumed maximum permissible
stress. Therefore, the DNV design guide has been selected to compare with our
calculated results and compute the maximum hoop stress condition. The detailed
calculation of maximum hoop stress with actual operation data of DNV design code
can be seen in Chapter 3, Section 3.1. Table 6.2 shows that the comparison between
the DNV design guide and our calculated result output data.
Table 6.2 tabulates the maximum hoop stresses under the following conditions:
(a)
Uniform tension of the loaded rope in Design codes and Hampes Solution.
(b)
The percentage difference between the design codes and our results is 19% for the
pulling load condition and 42% for the braking load condition, respectively. These
percentage difference will be used to determine the required thickness of the improve
design.
55
DNV Code
520
442
430
646
Particular
429
442
370.7
348.4
442
520
pressure
pressure
520
Decreasing
pressure
Uniform
42
19
pressure
Decreasing
DNV (%)
Table 6.2 Comparison between DNV design code and calculated result data of Hoop Stress
56
6.7
According to our calculated results, we found out that the other factor that can get a
revamping profitable design is to reinforce the thickness only in the certain area of the
winch drum, which will resist the higher compressive stress caused by the pulling or
braking load in the winch operations. As refer to the Figure 6.1 and 6.2, it can be
clearly seen that the maximum hoop stress occurred at around third quarter (=0.8)
from the near end of the drum with the drum thickness of 70 mm due to the pulling
load. Moreover, the maximum hoop stress also occurred at the same position in the
braking load process (Please see details in the section 6.4).
Even though the maximum hoop stress occurred at the same position between pulling
and braking load condition, the improve design in reinforced thickness of winch drum
will emphasize only on the pulling load condition as it gives more relevant data to see
the clearer visualization of the continuous coiling. However, the suggested improve
design guide will not only compute for pulling load, but also figure out for the braking
load as well. For convenience calculations, we separated three sections as shown in
Fig 6.6 which can apply the same formulae with this Hampe theory in separated
sections for the reinforced application thickness of the drum.
As can be seen in the Figure 6.5, the graph was plotted for the 200 tons pulling
loading condition throughout the winch drum with the required thickness of 60 mm.
The details specification is as follows:
(I)
Drum diameter
1000 mm
57
(II)
Drum Length
1775 mm
(III)
Drum thickness
60 mm
(IV)
65 mm
(V)
200 tons
(VI)
520 MPa
15.4
= 1.96 x 106 N
Hoop stress on the 60 mm drum after pulling load applied at respective position
0
Const
-90
S tress in M P a
=0
-180
=0.25
=0.5
-270
=0.8
-360
=1
-450
1
13
Wraps
17
22
27
Fig 6.5 Hoop stress at each respective positions on the drum applied by decreasing
pressure in uniform thickness of 60 mm
Table 6.3 Required thickness of the winch drum correlated with maximum load
Thickness
Maximum weight of
loading in Tons
and position
of the drum
stress MPa
Pulling
60
Permissible
200
Braking
Pulling
Braking
407
437
300
442
nd
52
200
435
442
300
th
58
As can be seen in the Figure 6.5 and Table 6.3, the maximum hoop stress occurs at
=0.8 which is around third quarter of the 60 mm drum and has a magnitude of 407
MPa and 437 MPa for puling and braking load, respectively. However, the winch
drum had a capacity of 27 wraps of wire rope onto the full length of the drum.
According to the Figure 6.5 of pulling load application, the position of highest hoop
stresses occurred at =0.8 which is around third quarter of the drum, which means it
occur between the (=0.7) 19th to (=0.88) 24th wraps on the drum. So that, the total of
6 wraps (from 0.7 to 0.88 ) which have to withstand the highest hoop stress between
382 to 407 MPa according to our calculated results. From this result, we could say
that a quarter of total wraps on the drum has compressed the maximum hoop stresses
on the drum. The rest of the wraps, other than between these wraps, withstand the
hoop stresses are 366 MPa or less.
As a result, we can reduce the thickness the drum which is from near end (=0) to 18th
wraps (=0.66) and 25th wraps (=0.9) to far end (=0). (The details illustration can be
observed in Figure 6.6 and 6.7 as below). As can be seen in Table 6.4 row (2), the
hoop stress occurred at the 18th wraps (=0.66) and had a magnitude of 400 and 435
MPa in pulling and braking load, respectively for a 52 mm thickness of winch drum.
59
Pressure (P)
y
x
Drum
Section 1
L
Near end
Section 3
Far end
t2=60mm thick
t1=52 mm thick
Load
Fig 6.6 Illustration of cylindrical shells affected by external decreasing pressure in
reinforced thickness of drum
Hoop stress on the variable thickness drum after pulling load applied at respective position
0
=0
S tress in M P a
-90
=0.25
-180
=0.5
-270
=0.8
=1
-360
-450
1
13
Wraps
17
22
27
Fig 6.7 Hoop stress at respective wraps on the drum applied by decreasing pressure in
reinforced thickness of drum
The above Figures 6.6 and 6.7 shows that how the reinforced thickness of the winch
drums should be fabricated and how the hoop stress exerted onto the drum in each and
every position along the winch drum.
60
(I)
Drum diameter
1000 mm
(II)
Drum Length
1775 mm
(III)
Drum thickness, t1
52 mm
(The thickness of 52 mm is from near end (=0) to 18th wraps (=0.66, 1170 mm) and
25th wraps (=0.9, 1560 mm) to far end (=0))
(IV)
Drum thickness, t2
(V)
65 mm
(VI)
200 tons
= 1.96 x 106 N
300 tons
= 2.94 x 106 N
(IX)
D/d ratio
15.4
(X)
(XI)
442 MPa
61
As above calculated thickness and their position, we can predict that the general form
of reinforced thickness into the certain area of the drum for fabrication is,
6.10
According to our calculated result, the following table 6.4 and 6.5 tabulate the
recommended thicknesses correlated with highest loadings for uniform thickness and
reinforced thickness, respectively.
62
60
3.
65
60
2.
3.
52
55
60
t1
200
200
300
300
300
407
376
349
Braking Pulling
load
load
437
403
375
442
442
442
Permissible
Braking stress MPa
Load
Maximum hoop
Stress in MPa
520
520
520
Material
Yield
stress
MPa
15.3
15.3
15.3
D/d
Ratio
200
200
200
Pulling
300
300
300
Braking
Maximum weight of
loading in Tons
407
376
349
Pulling
437
403
375
Braking
Maximum hoop
Stress MPa in t2
401
379
347
Pulling
435
412
377
Braking
Highest hoop
Stress MPa in t1
442
442
442
Permissible
stress MPa
520
520
520
Material
Yield stress
MPa
15.3
15.3
15.3
D/d
Ratio
65
65
65
Rope
Diameter
As mentioned details in Section 6.7 reinforced thickness calculation, t2 is from 0.66 L to 0.9 L and the rest is t1 for fabrication.
70
t2
Recommended
Thickness of
the drum (mm)
1.
Sr.
65
2.
200
Pulling
load
Maximum weight
of loading in Tons
Table 6.5 Recommended reinforced thickness of the winch drum correlated with maximum load
70
1.
Sr.
Recommended
Thickness of the
drum (mm)
Table 6.4 Recommended uniform thickness of the winch drum correlated with maximum load
65
65
65
Rope
Diameter
63