Weight Optimization of Extensible boom of

Telescopic Hydraulic Crane

Nilesh P. Darji, Atul Deshmukh and P.D. Solanki
L.D.College of Engineering, Ahemedabad, India.
Tecso Technology Solution, Baroda, India.
nilesh_me2008@yahoo.com
atul_301077@yahoo.com
purnikkumar@yahoo.com

Abstract- In this paper we have done the Finite
Element Analysis and weight reduction of Extensible
telescopic boom of Telescopic hydraulic crane using
Finite Element Analysis Software Ansys. Previous
work has been done on this type of crane or crane
structure is up to stress analysis using more than one
element in the Finite Element Analysis. Here we find
out the maximum stress induced in the boom model
with the max load carrying capacity according to the
loading chart prepared using SAEJ1078 standards
and kinematic force calculation software Design
View. This stress result is less than Yield and ultimate
strength of the material so we have option to optimize
the total weight of the boom. After reducing weight
of the boom we have done the stress analysis again
under same condition of loading as before reduce
weight and we got the maximum stress result is still
less than the yield and ultimate strength of the
material . As a result of this study further weight
reduction of the off highway vehicles and their
structures is proposed so we can minimize the overall
manufacturing cost by saving the expenditure on the
material. Model taken in this paper is Autogru 160.30
of an Italian Company Eurogru Amici. The analysis
has been done at the company Tecso Technology
Solution, Baroda.
KEYWORDS: - Telescopic Hydraulic Crane, boom,
FEA, Optimization, Design View.
1. INTRODUCTION
A telescopic hydraulic crane has a boom that
consists of a number of tubes fitted one inside the
other. A hydraulic or other powered mechanism
extends or retracts the tubes to increase or decrease
the total length of the boom. These types of booms
are often used for short term construction projects,
rescue jobs, lifting boats in and out of the water, etc. The
relative compactness of telescopic booms make them
adaptable for many mobile applications. Boom play
objective role in the load lifting operation and the
maximum direct effect of the stress is initializing from it
and effects to another attached assemblies of crane Some
times this crane are truck mounted to travel on highway
and eliminating the need of the special transportation for
crane.
Generally, these cranes are able to travel on highways,
eliminating the need for special equipment to transport the
crane. When working on the jobsite, outriggers are
extended horizontally from the chassis then vertically to
level and stabilize the crane while stationary and hoisting
Many truck cranes have slow-travelling capability (a few
miles per hour) while suspending a load. Great care must
be taken not to swing the load sideways from the direction
of travel, as most anti-tipping stability then lies in the
stiffness of the chassis suspension. Most cranes of this type
also have moving counterweights for stabilization beyond
that provided by the outriggers. Loads suspended directly
aft are the most stable, since most of the weight of the
crane acts as a counterweight. Factory-calculated charts (or
electronic safeguards) are used by crane operators to
determine the maximum safe loads for stationary
(outriggers ) work as well as (on-rubber) loads and
travelling speeds. This paper is a part of analysis and
optimization using the stress result getting from structural
analysis of telescopic hydraulic crane using ANSYS
11.0(FEA Software).
In this paper we have studied one step further than
previous authors work did up to analysis and modeling.
This paper represent the overall manufacturing cost
reduction by use of weight optimized model keeping the
same limit for the stress produced at the time of loading. In
this paper also incorporate one kinematic force calculation
software DESIGN VIEW which is very useful for the force
calculation for off highway vehicles.
2. EXTENSIBLE BOOM MODEL 3. FORCE CALCULATION USING DESIGN VIEW
DESCRIPTION
Nomenclature
Boom play a vital role for load lifted in crane the Cl_l = Length of cylinder
term telescopic hydraulic crane implies that the boom = 3720 < Cl_l < 6420
has the section more than one in telescopic manner.
Mcl = Mass of Cylinder = 1020 Kg
Here the telescopic boom has a five section of boom
and section 4 attached with Boom head sheave. With P_Cl = Pressure of Cylinder < Ps
advantages of lifting load at high elevation or at long Ps = Static Cylinder = 32.61 Mpa
horizontal reach , boom with automatic mechanism Cy_D = Cylinder Diameter = 310mm
of extend and retract of its section makes it compact Mlf = Mass of Lower Frame = 11996 Kg
and reliable for using at any desired mark. Here every
Muf = Mass of Upper frame = 1795 Kg
section has a half round shape from its middle to
bottom and square from middle to up. This type of
Mbo = Mass of boom = 7000 Kg
section gives the higher strength than the only square Cab = Mass of Cabin = 315 Kg
sections boom. Model taken for the FEA is attached Wi = Mass of Winch = 505 Kg
with the cylinder for giving constraints. On the crane Ax1 = Mass of first Axle = 4100 Kg
boom attached with its pivot point to the upper
Ax2 = Mass of second Axle = 3050 Kg
structure and it reach capacity controlled by
extracting and retracting hydraulic cylinder as shown
Ax3 = Mass of third Axle = 1595 Kg
in figure1. Ax4 = Mass of fourth Axle =1595 Kg
CgClx= Horizontal Dimensions from pivot
Point to CG of Cylinder
Boom 4
Cgxbo = Horizontal dimensions from
Boom Pivot point to CG of Boom
3 MaxR=Horizontal dimensions between
Boom 5 with
Boom Head Boom2 Load lifted point and front tip.
Boom 1 FliftF=Maximum Force lifted by the
(Base
boom) boom at the desired position

Cylinde
r Figure2:- DV file of 26.8m height and 8 m reach

Figure 1: Geometry and 3-D model of the

Extensible Boom
Model shown in figure made in pro-e wildfire 2.0
which is well known software for 3-D modeling of
component and its detail contains in it like its
drawing, dimensions, co-ordinate system, weight and
volume of each component etc. This Extensible boom
at its max extensible height 26.8 m and reach is 8 m.
After this whole model has been prepared,
rectangular pad made on the top surface and bottom
inner surface of the each boom for providing the
contact definition and giving sliding properties
between the boom sections with each other for the
FEA in Ansys. This assembly opens to the Ansys
workbench for further analysis.
 Design View is an easy-to-use 2D parametric of that load for preparing the final loading chart for the
CAD tool that helps designers and engineers capture operator.
and analyze design concepts and turn them into At 26.8 m height we have the below load lifted
working models. In this software the part or link calculation for the different horizontal reach of the boom
draw as 2-d drawing and import from DXF or any Reach (m) Actual Final Load Force
other cad software tool and gives the constraint and load lifted Lifted = (N)
variables values. According to that limit it calculates according 75%*FliftF FliftF*g
the force by moment equation that we write on the to DV (tones)
file(tones)
DV files. It also have feature to animate the part at
8 42.20 31.65 42200
different condition according to the variable limit 9 19.26 21.95 19260
given. Thus we can find the max load lifting capacity 10 24.3 18.23 2430
at different angle of boom and different height and 12 17.84 13.38 178.4
radius of the boom. By calculate at different angle of 14 13.82 10.37 138.2
boom regarding its height and radius range we 16 11.08 8.31 110.8
prepared one chart having Reach and Height 18 10.02 7.52 100.2
designated X-axis and y-axis accordingly is called 20 9.09 6.82 90.9
REACH DIAGRAM. With this reach diagram the 22 7.58 5.69 75.8
24 5.44 4.08 54.4
sheet of load carrying capacity made for user as a
Table1 : Force values at 26.8 m boom extension
load rating chart for final using range of the crane.
Note: - Taken g= 10(m/s) approximate because here we
Here in this boom, load condition taken in its
have to find stress distribution at its max stage and
full counter weight attached means 7200Kg and full
analysis also has to be done at max load lifted so we
extension of out riggers. Equation below is given the
taken 10 instead of 9.81 for the ease of calculation.
maximum force lifted at the specified position means
26.8 m height and 8 m horizontal reach. This
equation is based on the calculation carried out 4. FEM AND MESHING
according to the SAE 1063. Loading chart prepared Among the numerical techniques, the finite element
according to the equation of load lifted at any method is widely used due to the availability of many
position of the boom as below user-friendly commercial soft wares. The finite element
method can analyze any geometry, and solves both
FliftF= (Mbo*(Cgxbo-3415.13)+ stresses and displacement.FEM approximates the solution
Mcl(3415.13-CgClx)+ of the entire domain under study as an assemblage of
cab*(3415.13445.26)+ discrete finite elements interconnected at nodal points on
RG*(3415.13+0.17)+ the element boundaries. The approximate solution is
Mlf*(3415.13-34.70)+ formulated over each element matrix and thereafter
Wi*(3415.13+3206.87)+ assembled to obtain the stiffness matrix, and displacement
Ax4*(3415.13-1872)+ and force vectors of the entire domain. In this study finite
Ax3*(3415.13-472)+ element modeling is carried out by means of the Ansys
Ax2*(3415.13+2033)+ commercial package. For the meshing of the entire boom
Ax1*(3415.13+3828)+ we have to take some assumption regarding the model
CW*(3415.13+2762.91))/MaxR import in to the Ansys Work bench.
• Fillets chamfer and round edges are removed for
In above equation only bold variables Cgxbo and getting the good quality of the mesh.
CgClx only change according to change of the boom • Gaps are filled by addition of the material up to
position. Here 3415(mm) is the Front tip point from certain thickness
the pivot point of the crane. Taking moment of every • Subassemblies are made single part by the shrink
part of the crane by this point and we got above wrap method in pro-e to get the single part effect
equation By iterate at different reach of the boom on that assembly.
we made the loading chart for the max boom height.
• Additional co-ordinate system made at the boom
FliftF is not the final loading taken for the analysis
head sheaves to give the direction of load at the
as per the DIN and SAE standards ,as safety and
desired angle made by the combination of height
stability of the crane concern, we have to take 75%
and reach.
 In the Ansys workbench environment , remove all We gave the material properties as per below to the model
automatic contact define by the Ansys itself and give and this material has higher ultimate tensile and yield
the bonded contact between the pad and the boom strength compare to the structural steel.
surfaces according to the above model description. The properties of the material Weldox_900 which is
Now given the mesh command Ansys automatic specialized steel plate and used for Load carrying
generate mesh. The detail of mesh as per given structures having very high demands on low weight
below.
Body name Nodes Elements
Base boom (boom 1) 100827 53654 Table 4 :- Properties of the Weldox_900 material
Boom2 75098 40381 Young’s modulus 2 x 10 11 Pa
Boom3 72885 39809 Possion’s ratio 0.27
Boom4 85180 44739 Density 7850Kg/m3
Boom5 with sheaves 106638 58006 Thermal Expansion 1.2 x 10 -5 /oC
Cylinder 12889 6419 Tensile Yield Strength 9 x 108 Pa
Table 2 :- Nodes and Elements distribution Tensile Ultimate strength 9.4 x 108 Pa
Compressive yield strength 9 x 108 Pa
The element taken by the Ansys itself as per given Thermal Conductivity 60.5W/m oC
below. Specific Heat 434 J/kgoC
Generic Element Type Name Ansys name Relative permeability 10000
10 node Quadratic Tetrahedron Solid 187 Resistivity 1.7 x 10 -7
Quadratic Traingular Contact Conta 174
Quadratic Triangular Target Targe170
Table 3:- Types of element taken by Ansys

Table 4 :- Properties of the Weldox_900 material

Figure 3:- Meshing of the extensible boom

5 FEA SOLUTION AND RESULT

After meshing completion next step towards
optimization is static structural analysis and for that
we have to give the load as per shown in the figure 4
at the sheaves. This load acting vertical at the bottom
of the sheave at the boom angle of 70 degree with
horizontal line passing through the pivot point of the
boom. For the loading at the angle of 70 we made the
coordinate system at the sheaves as discussed above
Figure 4:-Vertical Load of 42209 N acting at sheaves
Here we took the max load applied at the height of
26.8m because if analysis safe for this load condition then
automatically become safe for further loading condition so
for that we have to take load at 8 m reach and it is 42209N.
Run analysis in Ansys workbench after completion of all
preprocesses like cylindrical support at the boom end and
cylinder end .
The results come out after long mathematical
procedure computed by the Ansys is Equivalent
Stress and Total Deformation of the boom. Now the
stress result is under the safe design stress criteria
according to calculation as per below
Safe Working Stress = Yield point stress
Factor of safety
= 900/2
= 450 Mpa>363.85Mpa
According to this result as per shown in the figure5 is
363.85Mpa which is less than 450 MPa means the
boom has safe for working to the applied load of
42209N and less than that.
Figure5=Equivalent Stress Result (Max=363.85MPa)
Total Deformation of the boom as shown in figure 6
and max. deformation of 0.174m occur at the sheaves
Figure 6 : Total Deformnation of boom(Max:0.174m)
6 WEIGHT OPTIMIZATION
Design optimization is a procedure to create an
optimum design performs intended functions and meets all
requirements likes stress level and keeps the total weight to
minimum. In this model we optimized weight by the shape
optimization in the Ansys workbench up to 20% its called
shape factor in Ansys environment. We gave the same
loading condition and shape factor we run the analysis and
getting result. This results are in the form of original mass
Optimized mass and marginal mass and also have
simulation of the boom for where we need to optimize the
mass so our basic function requirements are fulfilled
means working stress in less than the safe working stress.
In figure 7 we have done the shape optimization and got
the result for weight reduction.
Figure 7 = Shape optimization
Original mass of boom =6611kg
Optimized mass=5532.5kg
Marginal mass = 6.1251kg
Now this marginal weight of 6.1251kg have to remove
from the model by shown in to the simulation model with
red portion where we can remove material from the model
else model keep as same before. Now we remove material
by making holes and groves inside boom and cylinder.
We also reduce weight by less thicken material used for the
modeling of the boom. Here in this boom we removed
material using both methods. This optimized model
become the FEA model than further analysis run as per
same loading conditions and constraints as per before
optimization. Ansys Workbench environment run the
analysis and give the result which compare by the previous
result and concluded. In figure 8 the final boom stress
result shown which has a max stress is 402.23MPa which
is less than the 450MPa. Which indicated that the this
model is also acceptable .
 [3] Vincent STALON: “Model analysis of 3d
crane ,SISOM BUCHAREST-2004

[4] Alkin, C.: “ Solid modeling of

telescopic hydraulic crane and analysis
with finite element method.”M.Sc. thesis
,Istanbul Technical University ,Istanbul,
Turkey, 2004

[5] Company Website : www.eurogruamici.it

Figure 8 : final optimized model stress distribution.
[6] Kogan, J :Crane design : “Theory and
calculation of reliability” ,John Wiley &
7 CONCLUSION Sons,Newyork,1976
In this study unlike the other study we ahead
further one step of weight optimization using FEA
and we reduce weight though stress result still in
safe.
Stress(MPa Mass(kg)
)
Before Optimized 363.85 6611
After Optimized 402.23 5532.5
The proposed work of this study is still reduce the
weight by increasing the shape factor beyond 20%
and more weight reduction. Now this weight
reduction is ultimately effect the material used for
making the model. We have to use less material at
the manufacturing time thus by this study we can
save the expenditure on the material and also the
overall manufacturing cost which is revolutionary in
the field of this off highway vehicles.

ACKNOWLEDGEMENT
It is pleasure to acknowledge much stimulating
correspondence with Prof & Head P.D. Solanki of
L.D.College of Engineering and Mr. Atul Deshmukh,
Principal Engineer of Tecso Technology solution. It is
greatfully to acknowledge the support of Tecso
Technology Solution which provided the Model Data
of Telescopic Hydraulic Crane model Autogru
160.30.

REFERENCES

[1] Moavani,S. : Finite Element Analysis : theory

and application with ANSYS. New Jersey: Prentice
Hall, 1999.

[2] Anon, A: “New thinking in mobile crane

design”.cargo systems,Vol. 5, No.6, p.81