Description

This calculation note is for overhead crane design.

capacity of crane = 5 ton
Crane span: 23m
We are calculating a load based on IS 807:2006
We use SW simulation 21 to preform stress analysis for Crane because it is very user friendly, has better
material library and also gives appropriate results in comparison with others software’s available in the
market.

In our case it is the case of crane working without wind as the crane is of indoor type

 (Static load due to dead weight) + (working load) × (dynamic coefficient, Ψ)

 IMPACT FACTORS (Ψ)
 The impact loads caused in the hoisting operation are different in value according to the hoisting
speed, deflection of the girder, rope length, and are given by multiplying the impact factor.
 As our crane is a M5 type, the value of impact factor is 1.32.
 WORKING LOAD IS 5 TONS
 DUTY FACTOR
 The value of duty factor depends upon the group classification of the cranes. The main loads shall
be multiplied by the duty factors considering the working conditions and importance of the duty.
 As our crane is a M5 type, the value of duty factor is 1.06.
PRINCIPAL LOADS EXERTED ON THE STRUCTURE
 Total weight of crane = (weight of main girder × 2) + (weight of end carriage assembly × 2) +
bottom pulley block assembly = 6 tons.
 Total weight of main girder = 2.7 tons.
 Total weight of end carriage assembly = .5 tons.
 Total weight of bottom pulley block assembly = .2 tons.
ALLOWABLE STRESS

 In our crane for mild steel as per ASTM 36, the maximum permissible stress is 250 Mpa.
 The factor of safety is 1.4.

 The allowable safe stress is = = 178.57 Mpa

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LIMITING DEFLECTION OF GIRDER

 The maximum vertical deflection of the girder produced by the dead load, weight of the trolley
and rated load shall not exceed 1/750 of the span of the crane for more than 12 meters.
 The span of the crane is 23000 mm.
 So maximum vertical deflection = span × (1/750) = 23000 × (1/750) = 30.6 mm.

TYPES OF ANALYSIS

 STRUCTURAL ANALYSIS
 STATIC ANALYSIS
 BUCKLING ANALYSIS
 FATIGUE ANALYSIS
 HEAT TRANSFER ANALYSIS
 SHAPE OPTIMIZATION
 VIBRATIONAL ANALYSIS
 HARMONIC ANALYSIS

TYPES OF ANALYSIS CONSIDERED FOR EOT STRUCTURAL PARTS

 There are several types of analysis like static structural analysis, flexible dynamic analysis, rigid
dynamic analysis, harmonic response analysis, model analysis, linear buckling analysis, random
vibration analysis etc.
 Here we have considered static analysis and BUCKLING ANALYSIS for 5 ton EOT crane.
 By selecting this analysis option in SW simulation 21 we can get displacement, stresses, strain and
forces in structures caused by loads.

MAIN GIRDER
LOAD CASE IDENTIFICATION

Load case 1: hook at the centre of the span

Load case 2: hook at the either of the end sides of the span

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LOADS COMING ON MAIN GIRDER

 Following loads are considered in the finite element analysis of the structure assembly:
➢ Self weight of the structural parts.
➢ Horizontal forces acting on structure due to motion of the crane.
➢ Weight of crab assembly.
➢ Vertical forces due to externally lifted load.
To account for the effect of hoisting motion, duty and service conditions and acceleration and
deceleration while travelling, the concerned loads are multiplied by impact factor, duty factor as per
IS:807-2006

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VERTICAL FORCES DUE TO LIFTED LOADS

 For a class II M5 crane,

load in a vertical direction = impact factor × lifted load = 1.32 × 5= 6.6 T
 Total load acting vertically downward,
= (Duty factor × Load in vertical direction) + weight of hook
= (1.32 × 6.6) + .2 = 8.912 T

HORIZONTAL FORCES DUE TO LONGITUDINAL TRAVEL OF STRUCTURE

 For a class II M5 crane, the horizontal forces due to crane travel in longitudinal direction are
given as,
 Force value = 0.0632 × (Lifted load + Total weight of crane)
= 0.0632 × (5 + 6) = .7 T
 Considering the effect of Duty factor,
Total force = 1.06 × .7= .74 T.
For one girder we divide each horizontal and vertical force by 2
Vertical force for each girder = 8.912 *9.81/2= 44560 N
Horizontal force for each girder = .74 *9.81/2= 3685 N

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Model Information
Dimensions and details as per drawings

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Document Name and

Treated As Volumetric Properties
Reference
Mirror3
Mass:656.805 kg
Volume:0.0842058 m^3
Solid Body Density:7,800 kg/m^3
Weight:6,436.69 N

LPattern1[2]
Mass:12.0931 kg
Volume:0.00155039 m^3
Solid Body Density:7,800 kg/m^3
Weight:118.512 N

L angle L50X50X5(1)
Mass:80.5392 kg
Volume:0.0103255 m^3
Solid Body Density:7,800 kg/m^3
Weight:789.284 N

Boss-Extrude2
Mass:714.48 kg
Volume:0.0916 m^3
Solid Body Density:7,800 kg/m^3
Weight:7,001.9 N

LPattern1[10]
Mass:12.0931 kg
Volume:0.00155039 m^3
Solid Body Density:7,800 kg/m^3
Weight:118.512 N

LPattern1[7]
Mass:12.0931 kg
Volume:0.00155039 m^3
Solid Body Density:7,800 kg/m^3
Weight:118.512 N

LPattern1[4]
Mass:12.0931 kg
Volume:0.00155039 m^3
Solid Body Density:7,800 kg/m^3
Weight:118.512 N

Mass:12.0931 kg
Volume:0.00155039 m^3
LPattern1[1] Solid Body
Density:7,800 kg/m^3
Weight:118.512 N

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Mirror4[2]
Mass:10.6618 kg
Volume:0.0013669 m^3
Solid Body Density:7,800 kg/m^3
Weight:104.486 N

Mirror4[3]
Mass:49.608 kg
Volume:0.00636 m^3
Solid Body Density:7,800 kg/m^3
Weight:486.158 N

Split Line2
Mass:656.805 kg
Volume:0.0842058 m^3
Solid Body Density:7,800 kg/m^3
Weight:6,436.69 N

Cut-Extrude1[1]
Mass:10.6618 kg
Volume:0.0013669 m^3
Solid Body Density:7,800 kg/m^3
Weight:104.486 N

LPattern1[9]
Mass:12.0931 kg
Volume:0.00155039 m^3
Solid Body Density:7,800 kg/m^3
Weight:118.512 N

LPattern1[6]
Mass:12.0931 kg
Volume:0.00155039 m^3
Solid Body Density:7,800 kg/m^3
Weight:118.512 N

Cut-Extrude1[2]
Mass:12.0931 kg
Volume:0.00155039 m^3
Solid Body Density:7,800 kg/m^3
Weight:118.512 N

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Split Line1
Mass:447.495 kg
Volume:0.0573712 m^3
Solid Body Density:7,800 kg/m^3
Weight:4,385.45 N

Mirror6
Mass:80.5392 kg
Volume:0.0103255 m^3
Solid Body Density:7,800 kg/m^3
Weight:789.284 N

LPattern1[3]
Mass:12.0931 kg
Volume:0.00155039 m^3
Solid Body Density:7,800 kg/m^3
Weight:118.512 N

LPattern1[11]
Mass:12.0931 kg
Volume:0.00155039 m^3
Solid Body Density:7,800 kg/m^3
Weight:118.512 N

Boss-Extrude3
Mass:49.608 kg
Volume:0.00636 m^3
Solid Body Density:7,800 kg/m^3
Weight:486.158 N

Extrude-Thin2[1]
Mass:7.52522 kg
Volume:0.000964772 m^3
Solid Body Density:7,800 kg/m^3
Weight:73.7472 N

LPattern1[8]
Mass:12.0931 kg
Volume:0.00155039 m^3
Solid Body Density:7,800 kg/m^3
Weight:118.512 N

Mass:7.52522 kg
Volume:0.000964772 m^3
Mirror4[1] Solid Body Density:7,800 kg/m^3
Weight:73.7472 N

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LPattern1[5]
Mass:12.0931 kg
Volume:0.00155039 m^3
Solid Body Density:7,800 kg/m^3
Weight:118.512 N

Study Properties
Study name Static-Mid
Analysis type Static
Mesh type Solid Mesh
Thermal Effect: On
Thermal option Include temperature loads
Zero strain temperature 298 Kelvin
Include fluid pressure effects from Off
SOLIDWORKS Flow Simulation
Solver type Automatic
Inplane Effect: Off
Soft Spring: Off
Inertial Relief: Off
Incompatible bonding options Automatic
Large displacement Off
Compute free body forces On
Friction Off
Use Adaptive Method: Off
Result folder SOLIDWORKS document (E:\01-Smart
Engineering\2023 project\18-crane 1\analysis)

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Units
Unit system: SI (MKS)
Length/Displacement mm
Temperature Kelvin
Angular velocity Rad/sec
Pressure/Stress N/mm^2 (MPa)

Material Properties
Model Reference Properties
Name: 1.0037 (S235JR)
Model type: Linear Elastic Isotropic
Default failure Unknown
criterion:
Yield strength: 235 N/mm^2
Tensile strength: 360 N/mm^2
Elastic modulus: 210,000 N/mm^2
Poisson's ratio: 0.28
Mass density: 7.8 g/cm^3
Shear modulus: 79,000 N/mm^2
Thermal expansion 1.1e-05 /Kelvin
coefficient:

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Fixtures
Fixture name Fixture Image Fixture Details
Entities: 2 face(s)
Type: Fixed Geometry

Fixed-1

Resultant Forces
Components X Y Z Resultant
Reaction force(N) 0.000244141 44,560 -3,685 44,712.1
Reaction Moment(N.m) 0 0 0 0

Case 1Loads

Load name Load Image Load Details

Entities: 1 face(s)
Type: Apply normal force
Value: -44,560 N
Force-1

Entities: 1 face(s)
Type: Apply normal force
Value: -3,685 N
Force-2

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Contact Information

Contact Contact Image Contact Properties

Type: Bonded
Components: 1 component(s)
Options: Independent
mesh
Global Interaction

Mesh information
Mesh type Solid Mesh
Mesher Used: Curvature-based mesh
Jacobian points for High quality mesh 16 Points
Maximum element size 231.087 mm
Minimum element size 46.2173 mm
Mesh Quality High

Mesh information - Details

Total Nodes 108194
Total Elements 51519
Maximum Aspect Ratio 391.56
% of elements with Aspect Ratio < 3 0.00776
Percentage of elements with Aspect Ratio > 10 79.2
Percentage of distorted elements 0
Time to complete mesh(hh;mm;ss): 00:00:31
Computer name: AHMED-SAAD

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Case 1 static Resultant Forces

Reaction forces
Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N 0.000244141 44,560 -3,685 44,712.1

Reaction Moments
Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N.m 0 0 0 0

Free body forces

Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N 0.0535326 0.105844 0.0258732 0.121401

Free body moments

Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N.m 0 0 0 1e-33

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Case 1 static Study Results

Name Type Min Max

Stress1 VON: von Mises Stress 0.0N/mm^2 (MPa) 73.4N/mm^2 (MPa)
Node: 52926 Node: 62158

5 ton crane-Static-Mid-Stress-Stress1

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Name Type Min Max

Displacement1 URES: Resultant Displacement 0.000mm 13.529mm
Node: 53408 Node: 64050

5 ton crane-Static-Mid-Displacement-Displacement1

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Name Type Min Max

Strain1 ESTRN: Equivalent Strain 0.0 0.0
Element: 25335 Element: 29972

5 ton crane-Static-Mid-Strain-Strain1

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Name Type Min Max

Displacement2 UY: Y Displacement -13.296mm 0.000mm
Node: 62693 Node: 106117

5 ton crane-Static-Mid-Displacement-Displacement2

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Name Type Min Max

Displacement3 UZ: Z Displacement -0.012mm 2.512mm
Node: 62329 Node: 62253

5 ton crane-Static-Mid-Displacement-Displacement3

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Case 2 Loads

Load name Load Image Load Details

Entities: 1 face(s)
Type: Apply normal force
Value: -44,560 N
Force-1

Entities: 1 face(s)
Type: Apply normal force
Value: -3,685 N
Force-2

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Case 2 Resultant Forces

Reaction forces
Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N 0.000183105 44,560 -3,685 44,712.1

Reaction Moments
Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N.m 0 0 0 0

Free body forces

Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N -0.017704 -0.00643873 -0.0270047 0.0329264

Free body moments

Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N.m 0 0 0 1e-33

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Case 2 Study Results

Name Type Min Max

Stress1 VON: von Mises Stress 0.0N/mm^2 (MPa) 45.5N/mm^2 (MPa)
Node: 6531 Node: 63223

5 ton crane-Static-End-Stress-Stress1

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Name Type Min Max

Displacement1 URES: Resultant Displacement 0.000mm 2.005mm
Node: 53408 Node: 62305

5 ton crane-Static-End-Displacement-Displacement1

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Name Type Min Max

Strain1 ESTRN: Equivalent Strain 0.0 0.0
Element: 2763 Element: 27230

5 ton crane-Static-End-Strain-Strain1

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Name Type Min Max

Displacement2 UY: Y Displacement -1.983mm 0.000mm
Node: 5400 Node: 53487

5 ton crane-Static-End-Displacement-Displacement2

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Name Type Min Max

Displacement3 UZ: Z Displacement -0.004mm 0.295mm
Node: 62329 Node: 62943

5 ton crane-Static-End-Displacement-Displacement3

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Case 1 Buckling Study Results

Name Type Min Max

Amplitude1 AMPRES: Resultant Amplitude 0.0 0.0
Plot for Mode Shape: 1(Load Node: 85123 Node: 102619
Factor = -108.045)

5 ton crane-Buckling-Mid-Amplitude-Amplitude1

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Name Type Min Max

Amplitude2 AMPRES: Resultant Amplitude 0.0 0.0
Plot for Mode Shape: 2(Load Node: 85123 Node: 6381
Factor = 201.486)

5 ton crane-Buckling-Mid-Amplitude-Amplitude2

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Name Type Min Max

Amplitude3 AMPRES: Resultant Amplitude 0.0 0.0
Plot for Mode Shape: 3(Load Node: 85123 Node: 45802
Factor = 215.364)

5 ton crane-Buckling-Mid-Amplitude-Amplitude3

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Name Type Min Max

Amplitude4 AMPRES: Resultant Amplitude 0.0 0.0
Plot for Mode Shape: 4(Load Node: 85123 Node: 106521
Factor = 215.715)

5 ton crane-Buckling-Mid-Amplitude-Amplitude4

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Name Type Min Max

Amplitude5 AMPRES: Resultant Amplitude 0.0 0.0
Plot for Mode Shape: 5(Load Node: 85123 Node: 88415
Factor = 220.737)

5 ton crane-Buckling-Mid-Amplitude-Amplitude5

Mode List
Mode Number Load Factor
1 -108.05

2 201.49

3 215.36

4 215.72

5 220.74

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Case 2 buckling Study Results

Name Type Min Max

Amplitude1 AMPRES: Resultant Amplitude 0.0 0.0
Plot for Mode Shape: 1(Load Node: 85123 Node: 1175
Factor = -795.876)

5 ton crane-Buckling-End-Amplitude-Amplitude1

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Name Type Min Max

Amplitude2 AMPRES: Resultant Amplitude 0.0 0.0
Plot for Mode Shape: 2(Load Node: 85123 Node: 2034
Factor = -758.445)

5 ton crane-Buckling-End-Amplitude-Amplitude2

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Name Type Min Max

Amplitude3 AMPRES: Resultant Amplitude 0.0 0.0
Plot for Mode Shape: 3(Load Node: 85123 Node: 103360
Factor = -676.836)

5 ton crane-Buckling-End-Amplitude-Amplitude3

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Name Type Min Max

Amplitude4 AMPRES: Resultant Amplitude 0.0 0.0
Plot for Mode Shape: 4(Load Node: 85123 Node: 84950
Factor = 340.697)

5 ton crane-Buckling-End-Amplitude-Amplitude4

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Name Type Min Max

Amplitude5 AMPRES: Resultant Amplitude 0.0 0.0
Plot for Mode Shape: 5(Load Node: 85123 Node: 93740
Factor = 628.763)

5 ton crane-Buckling-End-Amplitude-Amplitude5

Mode List
Mode Number Load Factor
1 -795.88

2 -758.44

3 -676.84

4 340.7

5 628.76

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Conclusion
 From equivalent stress result of FEA in SW simulation21 of MAIN GIRDER, it is found that
maximum stress occurred is 73 Mpa in case 1 and is 43 Mpa for case 2 which is at the edge of
the fixed plate. So, it is safe.
 Now the average stress on whole girder is 50 which is less than allowable stress (178.57 Mpa) of
mild steel.
 The total deflection is 13 mm for case 1 and 2.5 mm for case 2 which is less than 30 mm.

For buckling study. Minimum compression safety factor is 201 , so crane girder is safe for lateral
buckling

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Table of Contents
Description .......................................... 1
Model Information ................................. 5
Study Properties .................................... 9
Units ................................................ 10
Material Properties ............................... 10
Fixtures ............................................. 11
Case 1Loads ........................................ 11
Contact Information .............................. 12
Mesh information .................................. 12
Case 1 static Resultant Forces .................. 13
Case 1 static Study Results ...................... 14
Case 2 Loads ....................................... 19
Case 2 Resultant Forces .......................... 20
Case 2 Study Results .............................. 21
Case 1 Buckling Study Results ................... 26
Case 2 buckling Study Results ................... 31
Conclusion.......................................... 36

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