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MODELLING AND STRESS ANALYSIS OF COLUMN BRACKET FOR ROTARY JIB CRANE

International Journal of Mechanical
Engineering
and Technology (IJMET),
ISSN 0976 – 6340(Print),
INTERNATIONAL
JOURNAL
OF MECHANICAL
ENGINEERING
AND
ISSN 0976 – 6359(Online), Volume 5, Issue 11, November (2014), pp. 130-139 © IAEME
TECHNOLOGY (IJMET)

ISSN 0976 – 6340 (Print)
ISSN 0976 – 6359 (Online)
Volume 5, Issue 11, November (2014), pp. 130-139
© IAEME: www.iaeme.com/IJMET.asp
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IJMET
©IAEME


MODELLING AND STRESS ANALYSIS OF COLUMN
BRACKET FOR ROTARY JIB CRANE
Subhash N. Khetre1,

S. P. Chaphalkar2,

Arun Meshram3

1, 3

Department of Mechanical Engineering, JSPM Rajarshi Shahu COE, IInd Shift Polytechnic,
Pune Maharashtra (India)
2
Head of Department, Department of Automobile Engineering, Pimpri Chinchwad, Polytechnic,
Pune Maharashtra (India)

ABSTRACT
In this paper, the method of final designing of column Bracket and boom for Material
handling jib crane system. The basic functions are determined for certain parameters of jib cranes as
yield strength, deflection of column Bracket and boom using stress analysis, displacement analysis.
A requirement for movement of heavy loads which are correspondingly difficult. Jib crane is design,
analyze and develop from three most prevalent material handling devices. They are Tower jib crane,
free standing Jib crane and jib crane with trusses. Among them the best design, higher strength and
greater life span crane has to be designed for future work. During the column Bracket and Boom
analysis, the Solid Works and COSMOS is used the analysis is carried out in two load steps. The
total analysis time is approximately twenty two hours taken by the software.
Keywords: Bracket, Jib Crane, I-Section Boom, Static Analysis, Solid Works and COSMOS.
I. INTRODUCTION
Today’s industry demands versatile, efficient, and cost effective equipment while at the same
time providing more flexibility along with significant savings through increased productivity. A jib
crane can help to improve material handling efficiency and work flow. Serious consideration should
be given to jib cranes for applications requiring repetitive lifting and transferring of loads within a
fixed arc of rotation.
The need of continual improvement in material handling technologies is a common feature of
many modern engineering endeavors. Engineering structures now encompass a wide range of
technologies from structure development, analysis, design, testing, production and maintenance.
Advances in material handling technologies have been largely responsible and major
performance improvements in many engineering structures and continue to be key in determining the
130



International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 11, November (2014), pp. 130-139 © IAEME

reliability, performance and effectiveness of such structures, designing of column Bracket and boom
for Material handling jib crane system.
II. ACTION PLAN
2.1 Selection of Crane (Phase-1)
While selecting the crane type, numbers of different factors are taken into account they are
capacity, operation requirement, application, design.
2.2 Selection Criterion (Phase-2)
Today’s industry demands versatile, efficient equipment while at the same time providing
more flexibility along with significant savings through increased productivity. A jib crane can help to
improve materials handling efficiency and work flow.
2.3 Work Requirement (Phase-3)
According to the below requirements free standing Jib Crane is best suitable.

Sr. No
1
2
3
4
5
6

Table No.1: Details of Work Requirement
Particular data
Details
Capacity
2 tons
Rotation
360o
Support
floor
Site
Outside weatherized work station
Height of lift
6000 mm.
Boom Length:
6000 mm.

III. DESIGN DETAILS OF BOOM
3.1 Selection of I-Section
Table No. 2: Details of Boom in I-Section shape
Sr. No
Particular data
Details
1
Type of Section
I section fillet type
2
Size
500×180 mm2
3
Material
Structural Steel
4
Mass per unit length
86.9 kg/m
5
Weight
564.85 kg.
3.2 Selection of Material of I Section: Structural Steel (M.S.)

Designation

MB500

Table No. 3: Indian standard medium weight beams
Depth Width
Web
Root
Root
(mm)
(mm)
Thick.
Thick. radius(mm)
(mm)
(mm)
A
H
b
Tw
Tr
R
110.74 500
180
10.2
10.2
17
Area
(cm2)

131

Toe
Radius
(mm)
r
8.5

MI
(cm4)

45218.3


International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 11, November (2014), pp. 130-139 © IAEME

3.3 Properties of Material Steel
• Young‫׳‬s Modulus : 2×105 MPa
• Poisson‫׳‬s Ratio : 0.3
• Density : 7.85×10-6 kg/mm
• Thermal Expansion : 1.25×10-5 per oC
• Tensile yield strength : 250 MPa
• Compressive yield strength : 250 MPa
• Tensile Ultimate strength: 460 MPa
• Compressive Ultimate strength : 0 MPa
• Thermal conductivity :6.05×10-2 watt/mm oC
• Specific Heat : 434 J/kg o C
3.4 Loads Defined
The loads acting on boom are defined as follows:
• Dead Load (DL): The weight of the beam and any other fixed item supported by the beam.
• Trolley/hoist Load (HL) The weight of the hoist and any other equipment attached to the
hoist.
• Lifted Load (LL): The weight of the item lifted along with all associated lift devices such as
slings, shackles, etc.

Figure.1: Indian standard medium weight
beams with Tapered Flanges

Figure.2: Dimensioning of Free Standing Jib
Crane

3.5 Actual load carried by the boom

Actual
load

Table No. 4: Details of Column Bracket
Lifted Load (LL) Hoist Load (HL) Dead Load (DL)
2000 kg
500 kg
243.10 kg

3.6 Total load acting on the boom
This is the total load carried by the beam
= LL+HL+DL = 2000+500+243.10 = 2743.1 kg
To balance the load and to check the yield strength of I section following calculations are given.
132


International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 11, November (2014), pp. 130-139 © IAEME

3.7 Calculations For 300×140 I-Section
To find reactions,
RX = 0 ; ∑MO = 0,
RY = 442 × 5.5 + 20 × 103 = 22431 N
Bending Moments: Bending Moment @ A
B.M. at A = 0
B.M. at 0 = - 20 * 103 * 5.5 – 442 * 5.5 * 103
M = 116685.25 Nm.
By Using Flexure Formula,
M/I = σ / Y = E / R
(11668.25 / 8306.3 * 10-8) = (σ / 125 * 10-3)
σ = 175.59 N/m2
OR σ = 175.59 MPa
As Yield strength σ (yield)
= 250 MPa……… (ISO Std.)

Figure.3- SFD and BMD diagrams for 20 KN
Loading condition
3.8 Check the Deflection in I Section
The Deflection calculated as below
δl = (wl3/3EI) + (wl4/8EI )

For Steel, E = 210 * 109 N/m2

IV. ANALYSIS RESULTS OF I-SECTION BOOM
The Static stress analysis is applied to calculation, which address the static analysis and
displacement analysis resulting.

Figure. 4-Static stress analysis of I-Section
Boom for 20 KN loading condition

Figure. 5- Static displacement analysis of Isection Boom for 20 KN loading condition.

The purpose of static analysis is to insure safety of the boom and supporting structure.
Sustained loads are by using self weight and operating conditions. In the analysis Solid Works and
COSMOS software is used and the analysis is carried out in two loading steps.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 11, November (2014), pp. 130-139 © IAEME

4.1 Analysis results of Boom




Stress (σ): The highest calculated stress will be in the order of 108 MPa.
Deflection (δ): The maximum deflection of the end point will be in the order of 8.38149 mm.
FOS: 2.5

V. DESIGN DETAILS OF COLUMN BRACKET
5.1 Design of Column Bracket

Sr. No
1
2
3
4
5
6
7

Table No. 5: Details of Column Bracket
Particular data
Details
Total
Mass = 640 kg
Type
Seamless pipe
Load
69748.28 N
OD
250 mm,
ID
200 mm
Material
Structural Steel
Mass
190 kg.

The Static stress analysis is applied to calculation, which address the static analysis and
displacement analysis resulting.

Figure.6: Failure in shear stress of
vertical upper Pipe of Column Bracket

Figure.7: Free body
diagram of forces on bracket

5.2 Design of Bracket clamper
Width
b = 180 mm, Thickness t = 40 mm.
In case of shearing Failure in shear stress of base plate of bracket as below:

Figure.8: Failure in shear stress of base
plate of bracket

-----Therefore, design is safe.

134


International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 11, November (2014), pp. 130-139 © IAEME

VI. ANALYSIS OF COLUMN BRACKET
The stress analysis is applied to calculation, which address the static analysis and
displacement analysis resulting. First two (2-D) dimensional brackets and Then 3-D Model of
Column Bracket are created for further analysis. The purpose of analysis is to insure safety of the
bracket and supporting structure. Sustained loads are by using self weight and operating conditions.

Figure.9: Two dimensional Model of
Column bracket.

Figure.10: Thee-D Model for analysis of
Column bracket

The analysis, the Solid Works and COSMOS is used the analysis is carried out in two load
steps.
6.1 Analysis results of bracket
• Stress (σ): The highest calculated stress will be in the order of 196 MPa.
• Deflection (δ): The maximum deflection of the end point will be in the order of 2.49 mm.
• FOS: 1.3

Figure.11: Static stress analysis of
Column bracket

Figure.12: Static displacement analysis of
Column bracket

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 11, November (2014), pp. 130-139 © IAEME

VII. WELDING DESIGN OF COLUMN
The designed Column Bracket consists of number of welding spots therefore size of weld are
very important point as we calculated below:
7.1 Design of Seamless Steel Pipe




Material: structural steel (0.20C 0.40Si 0.5Mn 0.035P 0.03S)
Size: 20’’ pipe (Ø500)
Thick: 12.5 mm.

7.2 Design of welding at column bracket
d = 250 mm,
l = 200 mm,

b = 50 mm.
τmax = 25 MPa

Figure.13: Welding to Column bracket.

Figure.14: Welding of bracket

The design of welding at column bracket
So , we need size and thickness,

Also, Bending stress,

Now final
Thickness t = 23 mm. Size = 16 mm.
7.3 Design of Welding of bracket
We are finding out welding parameters for welding different joints as below.
L =1000 mm.
τmax = 25 MPa.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 11, November (2014), pp. 130-139 © IAEME

,

,

VIII. RESULTS & DISCUSSIONS
8.1 Results of Boom
At first point of crane boom the load applied is 20 KN. At this point load is carried with the
help of a hook. The maximum displacement is 8.38 mm and maximum Stress is 175 MPa near the
upper portion where the assembly is done. In the Figure.4 it is shown by red colour.
Table No. 6: Stress analysis by using analytically for 20 KN loading condition
1 Minimum
100 MPa
2 Maximum
175 MPa
Table No. 7: Displacement analysis by using analytically for 20 KN loading condition
1
Minimum
1.91 mm
2
Maximum
6.156 mm
Table No. 8: Stress analysis by using Solid Works and COSMOS for 20 KN loading condition.
1
Minimum
108 MPa
2
Maximum
173 MPa
Table No. 9: Displacement analysis by using Solid Works and COSMOS for 20 KN loading
condition.
1
Minimum
1.00 mm
2
Maximum
8.38 m
8.2 Results of Bracket Column
At this point load is carried with the help of a Boom. The maximum displacement is 2.49 mm
and maximum Stress is 196 MPa near the upper portion where the assembly is done. In the Fig.11 it
is shown by red colour.
Table No. 10: Stress analysis of Column Bracket by Using Solid Works and COSMOS
1
Minimum
23 MPa
2
Maximum
196 MPa
Table No. 11: Displacement analysis of Column Bracket by using Solid Works and COSMOS
1
Minimum
1.00 mm
2
Maximum
2.49 mm
At first during the analysis, the Solid Works and COSMOS is used the analysis is carried out
in two load steps. The total analysis time is approximately twenty two hours taken by the software.

137


International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 11, November (2014), pp. 130-139 © IAEME

IX. COST ESTIMATION & PARTS LIST
All cost estimation & parts list as below in tabular form
Table No. 12: Cost Estimation of Column Bracket
Name of Parts
Qty. Cost per piece (Rs.) Total Cost (Rs.)
I-boom
1
80000
80000
Rope clamper
1
500
500
Bracket
1
11500
3.1 Bracket pipe
1
5500
5500
3.2 Bracket clamper
1
5000
5000
3.3 Rib
4
250
1000

Sr. No.
1
2

3

The designed Column Bracket consists of number of parts are listed below table.

Sr. No.
1

2

3

Table No. 13: Parts list of Column Bracket
Name of Parts
Materials
Weight
(kg)
I-boom
Structural steel
564.85
Rope clamper
Mild steel
10
plate
2.1 Rope clamper
40C8
1.5
plate pin
2.2 Rope clamper
40C8
0.5
Bracket
640
3.1 Bracket pipe
Structural steel
190
3.2 Bracket
Mild steel
440
clamper
3.3 Rib
Mild steel
10

Qty.
1

1
1
1
1
1
4

X. CONCLUSIONS
Jib Cranes vary widely in configuration, capacity, mode of operation, intensity of use,
working environment. The variety of forms, operating conditions, environmental factors make the
design of jib cranes challenging. Usually a new design need arises when existing cranes do not meet
the requirements for a new application. However, in most of the cases the required knowledge on
configuration and structure of a jib crane can be obtained from previously accumulated technical
information. The technical information is generally standardized. Besides that, the available jib crane
components are also well standardized all over the world and suitable for computer automated design
procedures. Since jib Crane design procedures are highly standardized. Thus it concluded that, we
have selected the suitable Design and Analysis of Bracket Column for Rotary Jib Crane.
XI. ACKNOWLEDGEMENT
I gratefully acknowledge Department of Mechanical Engineering of RSCOE (IInd Shift
Polytechnic) Tathawade, Pune (India), For technical support and providing the research facilities. I
would also like to thank to Dr. D. S. Bormane, Principal RSCOE, (IInd Shift Polytechnic) Pune and
Prof. S. Pattekari sir (DEAN) and Prof. Snehal Chopade, Head of Mechanical Engineering
138


International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 11, November (2014), pp. 130-139 © IAEME

Department for their help and dedication toward our research and related research, also our friends
for their directly & indirectly help, support and excellent co-operation.
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