Machine Design (MdP 2130)

Jib crane design

Mini project (2)

• Submitted by: -

NAME SEC ID

MOHAMED OSAMA MOHAMED HASSAN 4 9221480

 I) Design of beam CB:
• Static analysis:
1. (I) beam cross section dimensions:

From American wide flange beams ASTM A6 in metric units: I choose the beam cross section with
the following specifications:

(h=206mm, w=204mm, tw= 7.9mm, tf = 12.6mm, A=66.5x10^2 mm^2,

weight=52 x 10^-3 kg/mm, Ix=5268 x 10^4 mm^4)

2. (I) beam Material:

Structure steel grade S275JR with the following mechanical properties: ----{1}

Minimum Yield strength (MPa) Tensile strength (MPa) Minimum Elongation (%)
275 410 - 560 23

• F.B.D of Beam BC:

Equations of equilibrium:

Sigma moment around C = 0

(FAB sin (θ) x 4) + (FAB cos θ x 0.2) = (2000x9.81x5) + (0.51x10^3x6x3)

∴ FAB=41906.25N

Sigma forces about (X-axis) = 0

(FAB cos θ) = Cx

∴ Cx=33525 N

Sigma forces about (Y-axis) = 0

Cy= (FAB sin (θ)) - (2000 (9.81)) - (0.51x10^3x6)

∴ Cy=2463.75 N

area moment of inertia (I) was obtained by evaluating (I) for a solid (h x w) rectangular area, and then
subtracting the two rectangular areas that are not part of the cross section.
(𝑤−𝑡𝑤)
𝑤ℎ 3 ⋅(ℎ−2𝑡𝑓)3
𝐼= − 2( 2
)
12 12

𝑡𝑓2 ℎ 𝑡𝑓
(𝑤⋅ 2 )+((𝑡𝑤⋅(ℎ−2𝑡𝑓)⋅ 2 ))+(𝑡𝑓⋅𝑤⋅(ℎ− 2 ))
ȳ= (𝑡𝑤⋅(ℎ−2𝑡𝑓))+2(𝑡𝑓⋅𝑤)

𝑡𝑓 (ℎ−2𝑡𝑓) (ℎ−2𝑡𝑓) (ℎ−2𝑡𝑓)

𝑄 = (2 + ) ⋅ (𝑡𝑓 ⋅ 𝑤) + ( ⋅ (𝑡𝑤 ⋅ )) {Neglect}
2 4 2

According to Shigley For any common cross section beam, if the beam length to height ratio is
greater than 10, the transverse shear stress is generally considered negligible compared to the
bending stress at any point within the cross section.

In my situation the bean height = 206 mm, the beam length = 6000 mm

Therefore, the ratio is greater than 10.

∴ the transverse shear stress is generally considered negligible (No need to calc Q)

Therefore, ȳ = 103 𝑚𝑚 .
The critical axial location is at x=4 m where the shear force and the bending moment are both
maximum

Critical section is at B with Max bending = 20.64 x 10^6 N.mm

(20.64⋅106)(103)
𝜎𝑥 = (𝑀𝑦/𝐼) , 𝜎𝑥 = (𝑀ȳ/𝐼), 𝜎𝑥 = = 40.355 𝑀𝑃𝑎
5268⋅104

𝑉𝑄 𝑉𝑄
𝜏𝑥𝑦 = , 𝜏𝑥𝑦 = {neglected}
𝐼 𝑡𝑤 𝐼 𝑡𝑤

Now calculating the principal stresses using the relation:

Therefore, 𝜎1 = 𝜎𝑥 = 40.355 𝑀𝑃𝑎 , 𝜎3 = 0

𝜎𝑦 275
Applying Tresca: 𝜎1 = 𝐹.𝑠 , 𝐹. 𝑠 = 40.355 = 6.8 ≈ 7
 • Dynamic analysis:
𝑆𝑒 = 𝐾𝑓𝐾𝑠𝐾𝑟𝐾𝑡(𝑆𝑒 𝑑𝑎𝑠ℎ)
(𝑆𝑒 𝑑𝑎𝑠ℎ) = 0.5 𝑆𝑢𝑡 = 0.5 (560) = 280𝑀𝑃𝑎

𝐾𝑓 (𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝑓𝑖𝑛𝑖𝑠ℎ 𝑓𝑎𝑐𝑡𝑜𝑟) = 𝑒 𝑆𝑢𝑡 𝑓 = (4.51)(560−0.265 ) = 0.843 (Machined)

𝐴95 = (0.05)(ℎ)(𝑤) = 0.05 (206)(208) = 2142.4 𝑚𝑚2

𝐴95 2142.4
𝑑 𝑒𝑞𝑢𝑣𝑖𝑙𝑒𝑛𝑡 = √( ) = √( ) = 167.2 𝑚𝑚
0.0766 0.0766

𝐾𝑠(𝑆𝑖𝑧𝑒 𝑓𝑎𝑐𝑡𝑜𝑟) = 1.2489 𝑑 −0.112 = 1.2489 (167.2−0.112 ) = 0.7

𝐾𝑟(𝑅𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑦𝑡𝑓𝑎𝑐𝑡𝑜𝑟) = 0.82

𝐾𝑡(𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒𝑓𝑎𝑐𝑡𝑜𝑟 ) = 1

Then 𝑆𝑒 = (0.843)(0.7)(0.82)(1)(280) = 135.5 𝑀𝑃𝑎

( 19620 ⋅ 103 )(103 )

𝜎 max = = 38.4𝑀𝑃𝑎
5268 ⋅ 104

( 1020 ⋅ 103 )(103 )

𝜎 min = = 2 𝑀𝑃𝑎
5268 ⋅ 104

𝜎 𝑚𝑎𝑥 − 𝜎 𝑚𝑖𝑛 38.4 − 2

𝜎𝑎 = = = 18.2 𝑀𝑃𝑎
2 2
𝜎 𝑚𝑎𝑥 + 𝜎 𝑚𝑖𝑛 38.4 + 2
𝜎𝑚 = = = 20.2𝑀𝑃𝑎
2 2

For an unnotched beam Kf = 1.

𝐾𝑓 𝜎𝑎 𝜎𝑚 1
+ =
𝑆𝑒 𝑆𝑢𝑡 𝐹. 𝑠
18.2 20.2 1
+ = , 𝐹. 𝑠 = 5.9 = 6
135.5 560 𝐹. 𝑠
Safe design
 II) Design of member AB:
• Static Analysis:
Let The Material be as same as the I beam material
Assume F. s=3
Member AB is only subjected to Normal stress:
𝐹 41906.25
𝜎=𝐴= 𝜋 2 , Assume F. s=4
4
𝑑

𝑁 41906.25
𝜎1 = 𝜎𝑥 = = 𝜋 , 𝜎3 = 0
𝐴 𝑑 2
4
Therefore, d = 27.9, let d =30 mm

• Dynamic Analysis:
𝑆𝑒 = 𝐾𝑓𝐾𝑠𝐾𝑟𝐾𝑡(𝑆𝑒 𝑑𝑎𝑠ℎ)
(𝑆𝑒 𝑑𝑎𝑠ℎ) = 0.5 𝑆𝑢𝑡 = 0.5 (560) = 280𝑀𝑃𝑎

𝐾𝑓 (𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝑓𝑖𝑛𝑖𝑠ℎ 𝑓𝑎𝑐𝑡𝑜𝑟) = 𝑒 𝑆𝑢𝑡 𝑓 = (4.51)(560 −0.265 ) = 0.843

𝐾𝑠(𝑆𝑖𝑧𝑒 𝑓𝑎𝑐𝑡𝑜𝑟) = 1.2489 𝑑 −0.112 = 1.2489 (30−0.112 ) = 0.85

𝐾𝑟(𝑅𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑦𝑡𝑓𝑎𝑐𝑡𝑜𝑟) = 0.82

𝐾𝑡(𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒𝑓𝑎𝑐𝑡𝑜𝑟) = 1

Then
Se=(0.843)(0.85)(0.82)(1)(280)= 164.5 MPa
𝑁 41906.25
𝜎𝑚𝑎𝑥 = = 𝜋 = 59.3 𝑀𝑝𝑎
𝐴 2
4 30
𝑁 3585.9
𝜎𝑚𝑖𝑛 = = 𝜋 = 5.1 𝑀𝑝𝑎
𝐴 302
4
 𝜎 𝑚𝑎𝑥 − 𝜎 𝑚𝑖𝑛 59.3 − 5.1
𝜎𝑎 = = = 27.1 𝑀𝑃𝑎
2 2
𝜎 𝑚𝑎𝑥 + 𝜎 𝑚𝑖𝑛 59.3 + 5.1
𝜎𝑚 = = = 32.2 𝑀𝑃𝑎
2 2

For an unnotched Rod Kf = 1.

𝐾𝑓 𝜎𝑎 𝜎𝑚 1
+ =
𝑆𝑒 𝑆𝑢𝑡 𝐹. 𝑠
27.1 32.2 1
+ = , 𝐹. 𝑠 = 4.9 ≈ 5
164.5 560 𝐹. 𝑠

III) Design of connection of member AB and CB:

1. Pin design:
• Static analysis:
Let the material of pin be stainless steel grade 303 with following properties:

Yield strength =415 MPa, ultimate tensile strength=690 MPa

Assume F. s=1.5, length of pin=300mm

𝐹 41906.25
Failure due crushing stress: 𝜎 𝑐𝑟 = 𝐴 = (𝑑)(300)
𝐹 41906.25
Failure due to shear stress: 𝜏 = 2𝐴 = 𝜋
2( 4 𝑑2 )

2
𝜎 2 41906.25 2 41906.25
𝜏 max = √(( ) + 𝜏2 )= √(( ) +( 𝜋 ) )
2 2(𝑑)(300) 2 (4 𝑑 2 )

𝜎𝑦
𝜎 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑒 𝑓. 𝑠 415 415
𝜏 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 = = = = 𝑀𝑝𝑎
2 2 (1.5)(2) 3
2
41906.25 2 41906.25 415
For safe design: 𝜏 𝑚𝑎𝑥 < 𝜏 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑤 , √((2(𝑑)(300)) + ( 𝜋 ) )=
2 ( 4 𝑑2 ) 3

Therefore, d pin = 13.9 mm, Let d pin= 20 mm

 2. Bracket design:
• Static analysis:
Let the material of the bracket be AISI Type 304 Lwith the following properties:

Yield strength= 210 MPa, ultimate tensile strength= 564 MPa

Assume h= 3b, F.s = 1.5

4
𝐹𝑎𝑏 cos 𝜃 41906.25 (5)
Failure due to shear stress: 𝜏 = (ℎ)(𝑏)−𝑑 𝑝𝑖𝑛 (𝑏) = 4𝑏2 −20

3
𝐹𝑎𝑏 sin 𝜃 41906.25 ( )
5
Failure due to normal stress: 𝜎 = (ℎ)(𝑏)−𝑑 𝑝𝑖𝑛 (𝑏) = 4𝑏2 −20

3 2 4 2
𝜎 2 41906.25 ( ) 41906.25 (5)
𝜏 max = √(( 2 ) + 𝜏 2 )= √(( 2(4𝑏2 −20)5 ) + ( ) )
4𝑏2 −20
 𝜎𝑦
𝜎 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑒 𝑓. 𝑠 210
𝜏 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 = = = = 70𝑀𝑝𝑎
2 2 (2)(1.5)

Assume h=5 d pin, therefore, h= 100 mm, b= 100/3 mm

For safe design,𝜏 max ≤ 𝜏 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑤

2 2
√(12571.875 33525
(4𝑏2 −20)
) + (4𝑏2 −20) = 52.5

12571.875 2 33525 2
( ) +( 2 ) = 702
(4𝑏2 − 20) 4𝑏 − 20

Therefore, Safe design.

3. Bracket welding:
Direct shear: 𝜏= ((4/5) (41906.25)) /2 x 0.707 x 204 he

𝜏=158/he

𝜏= ((3/5) ((41906.25)) /2 x 0.707 x 204 he

𝜏=118.5/he

Iu= d^3 /6 = 1.4 x 10^6 mm^4

σ=M y /I = 38.5 / he

Assume electrode E 60, F.s =3

𝜏 max = 𝜏 absolute / F.s

158 2 118.5 2 38.52 172.5

√(( ) +( ) + ) =
ℎ𝑒 ℎ𝑒 ℎ𝑒 5

he=5.8 ≈ 6 mm
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