IJSRD - International Journal for Scientific Research & Development| Vol.
3, Issue 08, 2015 | ISSN (online): 2321-0613
Design and Analysis of 50 Tonne Crane Hook for Optimization
Mr. Nikhil R. Patel1 Mr. Nilamkumar S. Patel2
1
P.G. Student 2Assistant Professor
1,2
Department of Mechanical Engineering
1,2
Ipcowala Institute of Engineering & Technology, Dharmaj, India
Abstract—Hooks are employed in heavy industries to carry
tonnes of loads safely. These hooks have a big role to play
as far as the safety of the hoist loaded is concerned. With
more and more industrialization the rate at which these
hooks are forged are increasing. This work has been carried
out on one of the major hoist hook carrying a larger load
comparatively. So in present work the solid modeling and
finite element analysis of crane hook has been done using
Solidworks and ANSYS workbench. For analysis purpose
virtual model of crane hook is prepared by picking data
from design data book. Curved beam flexure formula is used
for determination of stresses in crane hook analytically.
Finite Element Analysis have been performed on trapezoidal
cross sections. To investigate the static stress results, both
finite element method and exact solution method are applied
and compare the stress results obtained by finite element and
exact solution methods. From the output of these analyses it
is observed that results obtained are in close agreement with
each other and maximum stress concentration occurs at
inner most surfaces.
Key words: Crane Hook, Curved Beam Flexure Formula,
Finite Element Analysis, Solidworks, ANSYS Workbench
I. INTRODUCTION
Crane and hoisting machine are used for lifting heavy loads
and transferring them from one place to another. Crane
Hooks are highly liable components that are typically used
for industrial purposes. Crane hooks with trapezoidal,
circular, rectangular and triangular cross section are
commonly used. Thus, such an important component in an
industry must be manufactured and designed in a way so as
to deliver maximum performance without failure. Products
are designated just like clevis hooks, grab hooks, or eye
hooks, and are used to connect lifting and rigging
attachments. Most industrial products like hooks, which are
forged from alloy steel, stainless steel, or carbon steel, and
then quenched and heat treated.
In this project work stress analyses of crane hook
with trapezoidal cross section and load carrying capacity is
50 tonne as per IS: 3815-1969 have been carried out.[1]
The crane hook is manufactured by EN3A steel
material having Indian standard 4367-1967. [2]
Firstly, the 3-D model of the hook is built used
Solidworks. Secondly, the static analysis on the hook is
proceeded by FEM software ANSYS. From the view point
of safety, the stress induced in crane hook must be analyzed
in order to reduce failure of hook.
II. FAILURE OF CRANE HOOKS
To minimize the failure of crane hook [3], the stress induced
in it must be studied. Crane is subjected to continuous
loading and unloading. This causes fatigue of the crane hook
but the fatigue cycle is very low. If a crack is developed in
the crane hook, it can cause fracture of the hook and lead to
serious Accident. In ductile fracture, the crack propagates
continuously and is more easily detectible and hence
preferred over brittle fracture. In brittle fracture, there is
sudden propagation of the crack and hook fails suddenly [4].
This type of fracture is very dangerous as it is difficult to
detect.
Strain aging embrittlement [5] due to continuous
loading and unloading changes the microstructure. Bending
stresses combined with tensile stresses, weakening of hook
due to wear, plastic deformation due to overloading, and
excessive thermal stresses are some of the other reasons for
failure. Hence continuous use of crane hooks may increase
the magnitude of these stresses and ultimately result in
failure of the hook.
III. METHODOLOGY
A virtual model of IS: 3815 lifting hook similar to actual
sample is created using SOLIDWORKS software and then
model was imported to ANSYS workbench for Finite
element stress analysis and the result of stress analysis are
cross checked with that of Curved beam flexure formula for
curved beams.
IV. STRESS CALCULATION OF CRANE HOOK
The crane hook is a curved beam [6], simple theory of
bending for shallow, straight beam does not yield accurate
results. Stress distribution across the depth of such beam,
subjected to pure bending, is nonlinear (to be precise,
hyperbolic) and the position of the neutral surface is
displaced from the centroidal surface towards the Centre of
curvature. In case of hooks as shown in Figure 1, the
members are not slender but rather have a sharp curve and
their cross-sectional dimensions are large compared to their
radius of curvature.[7]
Fig. 1: Curved beam with its cross section area
The curved beam flexure formula is in reasonable
agreement for beams with a ratio of curvature to beam depth
(𝑟𝑐 /h) > 5 (rectangular section). As this ratio increases, the
difference between the maximum stress calculated by
curved beam formula and the normal beam formula reduces.
The above equations are valid for pure bending. In case of
crane hooks, the bending moment is due to forces acting on
one side of the section under consideration. For calculations
the area of cross section is assumed to be trapezoidal [8].
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 Design and Analysis of 50 Tonne Crane Hook for Optimization
(IJSRD/Vol. 3/Issue 08/2015/149)

A. Calculation for 50 Tonne Crane Hook F

σd =
A
=19.464 N/mm2
Bending stress at the inner fiber,
M b Ci
σbi =
Aeri
= 144.533 N/mm2 (Tensile)
Bending stress at the outer fiber,
M b Co
σ bo = −
Aero
= - 93.426 N/mm2 (Compressive)
Combined stress at inner fiber,
σri = σd + σbi = 19.464 + 144.533
= 163.997 N/mm2 (Tensile)
Combined stress at outer fiber,
Fig. 2: Trapezoidal cross section of hook
σro = σd + σbo = 19.464 - 93.426
Load carrying capacity, F = 50 tonne
= 490500 N = - 73.962 N/mm2 (Compressive)
Inner dia. of hook, C = 240mm Maximum shear stress,
bi = 150 mm τmax = 0.5×σmax
bo = 60 mm = 0.5×163.997
Inner radius of curve beam, ri = C/2 =120 mm. = 81.5425 N/mm2 at inner fiber.
Outer radius of curve beam, ro = ri +C In exact solution method, a simple hook is
considered as curved beam and the maximum stress on inner
= 120+240
concave and the minimum stress on outer convex surfaces
= 360 mm.
Depth of the section, h = 240mm. are calculated as σmax = 163.997 N/mm2 and σmin = -73.962
Radius of the neutral axis, rn = N/mm2 respectively.[9]
1
h (bi + bo ) V. DIMENSIONS, DESIGNATION AND MATERIAL OF HOOK
2
bi ro −bo ri ro
ln − (bi − bo ) The hook having Trapezoidal cross section as per IS: 3815-
h ri
1 1969 has been considered for modeling in SOLIDWORKS
240 (150 + 60)
2 software. Dimensions chosen for hook are tabulated below:
(150×360)−(60×120) 360
ln − (150 − 60) Dim. Dim.
240 120 Parameters Parameters
= 202.851 mm. (mm) (mm)
Distance of centroidal axis from inner fiber, D 240 R 30
C1 = S 180 Ra 170
h bi + 2bo b 150 Rb 130
[ ] h 240 Rc 320
3 bi + bo
240 150 + 120 d 160 Rd 65
= [ ] d1 140 Re 240
3 150 + 60
=102.857 mm. l 330 Rf 280
Radius of centroidal axis, rc = ri + C1 l1 150 Rg 40
= 120+102.857 l2 120 Rℎ 5
= 222.857 mm L 730
Distance of neutral axis to centroidal axis, Table 1: Dimensions of crane hook
e = rc − rn = 222.857 – 202.851
= 20.006 mm.
Distance of neutral axis to inner radius,
Ci = rn − ri = 202.851 – 120
= 82.851 mm.
Distance of neutral axis to outer radius,
Co = ro − rn = 360 – 202.851
= 157.149 mm.
Distance from centroidal axis to force, l = rc =222.857 mm.
1
Area of cross section, A = h(bi + bo )
2
1
= 240(150 + 60)
2
2
= 25200 mm
Bending moment about centroidal axis,
Mb = F. l = 490500×222.857 = 1.093×108 N.mm
Direct stress, Fig. 3: Geometry of the single hook

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 Design and Analysis of 50 Tonne Crane Hook for Optimization
(IJSRD/Vol. 3/Issue 08/2015/149)

Type of material used for crane hook is EN3A steel For the selection of static analysis fixed support is chosen at
material having Indian standard 4367-1967. The material shank end and the force is applied in y direction for selected
properties are: materials of structural steel, now the solution is let to solve
1) Ultimate tensile strength 50-60 kg⁄mm2 and Von-mises stresses are detected for trapezoidal hook.
2) Yield stress(Min) 29 kg⁄mm2 For analyzing the cross-section of the crane hook after and
3) Elongation ( Min ) 20% when it is designed in the SOLIDWORKS, loads are applied
4) Hardness 140-180 BHN to check that how much load the designed crane hook with
stands. The process of applying load and the results obtained
VI. PREPARATION OF CAD MODEL OF HOOK in the Ansys are indicated below.
For generation of CAD model of crane hook various
geometrical features and dimensions are selected from IS:
3815-1969. Some features are approximated for
simplification. SOLIDWORKS-2014 software is used for
creating solid model of hook. Complete Solid CAD model is
prepared which is shown in fig.4 and it is saved in .igs
format.

Fig. 7: Boundary Conditions and Application of Load

Fig. 4: SolidWorks model of crane hook.

VII. STRESS ANALYSIS USING FEM

The solid CAD model in .IGS format is imported to ANSYS
for FEA. Meshing is important part of Finite Element
Method. The mesh taken has Tetrahedron shape. Simulation
process meshing of the model is generated as shown in Fig.5
the mesh details done in the CAD model is shown in Table-
2. The nodes and elements created by meshing are given
below: [10]
Fig. 8: Fixed Support

Fig. 5: ANSYS .IGS file from SOLIDWORKS

Nodes 14127
Elements 8114
Fig. 9: Equivalent (Von-Mises) Stress Distribution
Table 2: Mesh details

Fig. 6: Meshed model of crane hook. Fig. 10: Total Deformation

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 Design and Analysis of 50 Tonne Crane Hook for Optimization
(IJSRD/Vol. 3/Issue 08/2015/149)

REFERENCES
[1] IS-3815-1969 Specification for forged crane hook.
[2] IS-4367-1967, ‘Specification for alloy and tool steel
Forging for general industrial use’.
[3] B. Ross, B. McDonald and S. E. V. Saraf, “Big Blue
Goes Down. The Miller Park Crane Accident,”
Engineering Failure Analysis, Vol. 14, No. 6, 2007 pp.
942-961.
[4] J. Petit, D. L. Davidson and S. Suresh, “Fatigue crack
Growth under Variable Amplitude Loading,” Springer
Publisher, New York, 2007.
[5] Y.yokoyamal, "Study of Structural Relaxation-
Induced Embrittlement of Hypoeutectic Zr-Cu- Al",
Fig. 11: Maximum Shear Stress
Ternary Bulk Glassy Alloys, Acta Material, Vol. 56,
No. 20, pp. 6097-6108, 2008.
VIII. COMPARISON OF STRESSES
[6] Curved Beam Analysis.
For the model of crane hook, the induced stresses as www.roymech.co.uk/Useful_Tables/Beams/Curved_be
obtained from analytical calculations are compared with ams.html
results obtained by FEA software. [11] [7] Rashmi Uddanwadiker, “Stress Analysis of Crane
A. ANSYS v/s Analytical Hook and Validation by Photo-Elasticity”,
Engineering, 2011, 3, 935-941.
Innermost point of section: [8] H. A. Rothbart, “Mechanical Design Handbook:
Max stress by ANSYS= 149.09 N/mm2; Measurement, Analysis, and Control of Dynamic
Max stress analytically= 163.997 N/mm2 Systems,” McGraw-Hill, Columbus, 2006.
% error = (163.997 – 149.09)/149.09 = 9.99 % [9] L.S. Srinath, “Advanced Mechanics of solids”, 3rd
Outermost point of section: edition, pp.: 209-216.
Stress by ANSYS= 67.595 N/mm2; [10] G. U. Rajurkar, Dr. D. V. Bhope et. al, “Investigation
Stress analytical= 73.962 N/mm2; Of Stresses In Crane Hook By FEM,” International
% error = (73.962-67.595)/67.595 = 9.41 % Journal of Engineering Research & Technology, ISSN:
Stresses obtained for the hook by ANSYS and Curved beam 2278-0181, Vol. 2 Issue 8, August – 2013, pp. 117-
flexure formula is tabulated below: 122.
Outer stress [11] Yogesh Tripathi,” Comparison of stress between
Inner Stress (MPa)
(MPa) winkler-bach theory and ANSYS Finite Element
Analytical 163.997 73.962 Method for crane hook with a Trapezoidal cross-
ANSYS 149.09 67.595 section”.Volume:02 Issue: 09 sep-2013.
% Error 9.99 9.41
Table 3: ANSYS and Curved beam flexure formula

IX. DESIGN IMPROVEMENT

From the stress analysis we have observed the cross section
of max stress area. If the area on the inner side of the hook
at the portion of max stress is widened then the stresses will
get reduced. Thus the design can be modified by increasing
the thickness on the inner curvature so that the chances of
failure are reduced considerably. This model has an
important meaning to design larger tonnage lifting hook
correctly.

X. CONCLUSION
The complete study is an initiative to establish a FEA
procedure, by validating the results, for the measurement of
stresses. For reducing the failures of hooks the estimation of
stresses, their magnitudes and possible locations are very
important. The main aim of this paper is to improve quality
of crane hook to withstand bending stress and structural
stresses and at the same time reduce stress concentration of
the crane hook. So the further scope of work is optimization
of design of crane hook by changing parameters like inner
and outer thickness of crane hook cross section.

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