ENGINEERING ANALYSIS ON SPREADER BEAM BY USING

MANUAL CALCULATION AND SOLIDWORKS SIMULATION

SOFTWARE

This report submitted in accordance with requirement of the Universiti Teknikal

Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Manufacturing Process) (Hons.)

by

MOHD NOR EFFENDY BIN NEK MAN

B 051010077

890628-08-5175

FACULTY OF MANUFACTURING ENGINEERING

2013

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: ENGINEERING ANALYSIS ON SPREADER BEAM BY USING MANUAL CALCULATION AND SOLIDWORKS SIMULATION SOFTWARE

SESI PENGAJIAN: 2012/13 Semester 2

Saya MOHD NOR EFFENDY BIN NEK MAN

mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan

untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan

pertukaran antara institusi pengajian tinggi.

4. **Sila tandakan (√)

SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysiasebagaimana yang termaktub

dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan

oleh organisasi/badan di mana penyelidikan dijalankan)

Alamat Tetap:

No. 125, Lorong Suara Sepakat,

Kampung Lubuk Katak,

35000 Tapah, Perak D.R.

Tarikh: 12/06/2013

Disahkan oleh:

Cop Rasmi:

Tarikh: _______________________

** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.

FAKULTI KEJURUTERAAN PEMBUATAN

Rujukan Kami (Our Ref) : Rujukan Tuan (Your Ref):

Pustakawan 12/06/2013 Perpustakaan UTeM Universiti Teknikal Malaysia Melaka Hang Tuah Jaya, 75450, Melaka Saudara, PENGKELASAN LAPORAN PSM SEBAGAI SULIT/TERHAD LAPORAN PROJEK SARJANA MUDA KEJURUTERAAN PEMBUATAN (MANUFACTURING PROCESS): MOHD NOR EFFENDY BIN NEK MAN Sukacita dimaklumkan bahawa Laporan PSM yang tersebut di atas bertajuk “Engineering analysis on spreader beam by using manual calculation and SolidWorks simulation software” mohon dikelaskan sebagai *SULIT / TERHAD untuk tempoh LIMA tahun dari tarikh surat ini. 2. Hal ini adalah kerana IANYA MERUPAKAN PROJEK YANG DITAJA OLEH SYARIKAT LUAR DAN HASIL KAJIANNYA ADALAH SULIT. Sekian dimaklumkan. Terima kasih. Yang benar, ________________

* Potong yang tidak berkenaan

NOTA: BORANG INI HANYA DIISI JIKA DIKLASIFIKASIKAN SEBAGAI SULIT DAN

TERHAD. JIKA LAPORAN DIKELASKAN SEBAGAI TIDAK TERHAD, MAKA

BORANG INI TIDAK PERLU DISERTAKAN DALAM LAPORAN PSM.

UNIVERSITI TEKNIKAL MALAYSIA MELAKA Karung Berkunci No.1752, Pejabat Pos Durian Tunggal, 76109 Durian Tunggal, Melaka Tel : 06-331 6019/6429 Faks : 06-331 6411/6431 Email : fkp@utem.edu.my

I hereby, declared this report entitled “ Engineering analysis on spreader beam by

using manual calculation and SolidWorks simulation software” is the results of my

own research except as cited in references.

Signature : ………………………………………….

Author’s Name : MOHD NOR EFFENDY BIN NEK MAN

Date : 12 / 06 / 2013

DECLARATION

APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM

as a partial fulfillment of the requirements for the degree of Bachelor of

Manufacturing Engineering (Process) (Hons.). The member of the supervisory is

as follow:

………………………………

(Dr. Md Nizam Bin Abd Rahman)

i

ABSTRAK

Laporan ini berkaitan dengan projek industri yang menerangkan satu analisa

kejuruteraan mengenai spreader beam yang digunakan di Syarikat M. Spreader beam

adalah digunakan untuk mambantu proses mengangkat barangan khususnya untuk

barangan yang panjang. Walau bagaimanapun, safe working load (SWL) bagi

spreader beam ini tidak ketahui. Analisis matematik dan Finite element analysis

(FEA) menggunakan SolidWorks 2011 perisian simulasi digunakan untuk

mengenalpasti kebolehan untuk menahan beban berdasarkan reka bentuk spreader

beam. Di dalam analisis ini, 1.5 Ton digunakan sebagai beban kerja. Beban ini

adalah beban maksima bagi spreader beam yang telah dipilih. Berdasarkan pengiraan

matematik tekanan maksima adalah 88.53 MPa manakala daripada FEA analisis

tekanan maksima adalah 92.52 MPa. Terdapat 4.3% perbezaan antara kedua-dua

keputusan ini. Had SWL adalah 95 MPa berdasarkan factor of safety lima. Kedua-

dua keputusan ini tidak melebihi had SWL. Ini bermaksud, spreader beam ini

selamat untuk mengangkat beban maksima yang digunakan oleh Syarikat M seberat

1.5 ton. Reka bentuk Lifting lug telah dicadangkan bagi meningkatkan prestasi

spreader beam yang bersesuaian dengan penggunaannya di Syarikat M.

ii

ABSTRACT

This project is industrial related project that focused on engineering analysis of

spreader beam used in Company M. The spreader beam was used in hoisting process

usually for the long objects. However, safe working load (SWL) of the spreader

beam was unknown. The mathematical analysis and Finite Element Analysis (FEA)

using SolidWorks 2011 simulation software were used to identify the loading

capacity of spreader beam design. In the analysis, 1.5 ton load was used as the

working load. This load is the maximum load to be hoisted based on Company M for

selected spreader beam. Based on mathematical calculation the maximum stress

obtained is 88.53 MPa while from FEA simulation maximum stress is 92.52 MPa.

There is 4.3% difference between these two results. The SWL limit is determined as

95 MPa based on factor safety of five. Both of the results did not exceed the SWL

limit. That mean, spreader beam is safe to lift the maximum load specifed by

Company M which is 1.5 ton. New Lifting lug design was purposed to improve

spreader beam performance suited to its application in Company M.

iii

DEDICATION

To my beloved parents

iv

ACKNOWLEDGEMENT

First and foremost, I would like to express my appreciation to my final year project

supervisor, Dr. Md Nizam Bin Abd Rahman and Production Manager Company M,

Mr. Cheong Yew Leong for his guidance and support during completing this project.

Great appreciation also gives to my lectures and all staff in Faculty of Manufacturing

Engineering especially to the technician that patient in helping during prepares the

final product. Not forget, I am gratefully thanks to our colleague, Universiti Teknikal

Malaysia Melaka (UTeM) for providing enough material and good facilities in the

campus.

My sincere appreciation also extends to all my fellow colleagues and others who

have provided assistance at various occasions. Their views and tips are useful indeed

to finish up my project reports. Last but not least, I also would like to thanks to all

my family members that give fully support on completing this project.

v

TABLE OF CONTENT

Abstrak i

Abstract ii

Dedication iii

Acknowledgement iv

Table of Content v

List of Tables viii

List of Figures ix

List Abbreviations, Symbols and Nomenclatures xi

CHAPTER 1: INTRODUCTION 1

1.1 Background 1

1.1.1 Company background 1

1.1.2 Project background 2

1.2 Problem statement 2

1.3 Objective 3

1.4 Scope 4

CHAPTER 2: LITERATURE REVIEW 5

2.1 Introduction of spreader beam 5

2.2 Current design of spreader beam 7

2.2.1 Modular spreader beam 7

2.2.2 Fixed spreader beam 8

2.2.3 Castellated spreader beam 8

2.2.4 Telescopic spreader beam 9

2.2.5 H lifting frame 9

2.2.6 Spreader frame 10

2.3 Spreader beam design 10

2.4 Mathematical analysis 11

2.4.1 Force diagram 12

vi

2.4.2 Maximum stress 14

2.4.3 Shear capacity of beam 14

2.4.4 Bending capacity of beam 15

2.4.5 Maximum displacement 15

2.4.6 Lifting lugs potential failure 16

2.5 SolidWorks 2012 Simulation software 18

2.5.1 Finite element analysis method using SolidWorks 2012 Simulation 18

2.6 Safe working load and factor of safety 21

2.7 Summary 21

CHAPTER 3: METHODOLOGY 22

3.1 Research need 22

3.2 Gantt chart 23

3.3 Project flow chart 24

3.4 Data collection 26

3.3.1 Spreader beam dimension 27

3.3.2 Material and beam properties 28

3.3.3 Factor of safety 29

3.3.4 Working condition 29

3.5 Data analysis 30

3.4.1 Mathematical analysis 30

3.4.2 FEA analysis using SolidWorks 2012 32

3.4.3 Safe working load calculation 38

3.6 Summary 38

CHAPTER 4: RESULT AND DISCUSSION 39

4.1 Information on the Spreader beam 39

4.2 Mathematical analysis 41

4.3 FEA analysis using SolidWorks 2011 49

4.3.1 Stresses and displacement study 50

4.4 Comparison between mathematical and FEA analysis 57

4.5 Safe working load 58

4.6 Proposed improvement spreader beam design 58

vii

4.6.1 Suggestion improvement spreader beam design 59

4.6.2 Mathematical analysis 61

4.6.3 FEA analysis using SolidWorks 2011 64

4.7 Comparison between before and after improvement design 66

4.8 Summary 68

CHAPTER 5: CONCLUSION AND RECOMMENDATION 69

5.1 Conclusion 69

5.2 Recommendation 70

REFERENCES

APPENDICES

viii

LIST OF TABLES

3.1 Gantt chart 23

3.2 ASTM A36 Steel material properties 28

3.3 I-beam dimension and parameter 29

3.4 Formula for mathematical analysis 31

4.1 Material properties 40

4.2 Other properties 40

4.3 Mathematical analysis result 49

4.4 Model information 50

4.5 Material properties 51

4.6 Fixture 51

4.7 Load 52

4.8 Mesh information 53

4.9 Stress study result 54

4.10 Displacement study result 56

4.11 Comparison result 57

4.12 Result mathematical analysis 63

4.13 Stress study result 64

4.14 Displacement study result 66

4.15 Comparison between before and after improvement design 67

ix

LIST OF FIGURES

1.1 Spreader beam (Company M factory) 3

2.1 Basic spreader beam 6

2.2 Spreader beam with two upper lifting lugs 6

2.3 Shackles 6

2.4 Oblong, sling and hook 6

2.5 Modular spreader beam 7

2.6 Fixed spreader beam 8

2.7 Castellated spreader beam 8

2.8 Telescopic spreader beam 9

2.9 H lifting frame 9

2.10 Spreader frame 10

2.11 Spreader beam 11

2.12 Sign conversion for shear and moment bending 13

2.13 Example of free body diagram, shear diagram and bending

moment diagram

13

2.14 Tension failure 16

2.15 Tearing tension fracture 17

2.16 Shear force 18

2.17 Mesh 20

2.18 Displacement plot 20

2.19 Stress plot 20

3.1 Methodology flow chart 24

3.2 Spreader beam dimension 27

3.3 Solid model of spreader beam 32

3.4 How to change a model material 33

3.5 Material window 33

3.6 Upward force 34

x

3.7 Starting a new study 34

3.8 Fixture pane and Force/Torque pane 35

3.9 Mesh window and result folder 36

3.10 Mesh 36

3.11 Stress plot 37

3.12 Displacement plot 37

4.1 Free body diagram 42

4.2 Shear force diagram 42

4.3 Bending moment diagram 42

4.4 Fixture position 52

4.5 Load position 52

4.6 Von mises stress average 54

4.7 Center lifting lug stress analysis 55

4.8 Side lifting lug stress analysis 55

4.9 Existing spreader beam 59

4.10 Improvement design 59

4.11 Dimension for improvement design 60

4.12 Von Mises average 65

4.13 Center stress analysis 65

xi

LIST OF ABBREVIATIONS, SYMBOLS AND

NOMENCLATURE

A - Area I-beam ( )

AISC - American institute of steel construction

ASME - The American society of mechanical engineers

ASTM - American Society for Testing and Materials

- Least plate width at side of holes (mm)

CAE - Computer aided engineering

e - Distance edge of hole to edge of plate parallel to load (mm)

E - Young’s modulus ( )

F - Design load (N)

FEA - Finite element analysis

FEM - Finite element method

FOS - Factor of safety

- Allowable ultimate tensile strength ( )

- Bending force ( )

- Yield strength ( )

I - Moment of inertia ( )

L - Length (mm)

N - Newton

SWL - Safe working load

T - Plate thickness (mm)

V - Allowable shear force (N)

Y - Perpendicular distance from neutral axis (mm)

σ - Stress

ᵹ - Deflection

1

This chapter explains the background of this research, company background,

problem statement, objective, scope and introduction of spreader beam. This project

has been carried out based on the industrial requirement from Company M.

1.1 Background

The background of this research is divided with two parts which is company

background and project background.

1.1.1 Company background

Company M manufactures a comprehensive range of overhead travelling crane,

hoist, warehouse truck and wide variety of industrial products such as gondolas, dock

levellers, monorail systems and automated car parking system. Company M was

established in 1972 and operates within a close knit regional network in Singapore

(headquarters), Indonesia, Vietnam, Thailand and Taiwan. Company M is supported

by eight facilities, over 35 companies, and sales offices.

INTRODUCTION

CHAPTER 1

2

1.1.2 Project background

The primary aim of all design is to ensure that the structure performs well during

their function and design. The design of the structure must capable of carrying the

loads safely. This require of the designer to make realistic estimates of the strength of

the materials composing the structure and the loading to which it may be subject

during a basic design (Chanakya, 1994). This project is to perform mathematical

analysis and simulation analysis to determine safe working load (SWL) of the

spreader beam based on the working environment and the use of spreader beam at

the Company M factory. The mathematical analysis and simulation analysis of the

structure is considered in static condition. This project is using SolidWorks 2011

Simulation software to create drawing and simulation analysis according on

company requirements.

1.2 Problem statement

In the Company M factory, overhead crane and lifting equipment including spreader

beam extensively utilized. A spreader beam function is used to assist in the hoisting

process usually for the long objects. However, load capacity of the spreader beam is

unknown. The spreader beam product is not available in this region. Due to cost

consideration Company M make their spreader beams with their own fabrication

facility. Due to lack of engineering analysis the safe working load of this spreader

beams has not been specified. The factory have several spreader beams of different

sizes and unknown loading capacity. This project focuses only on a single spreader

beam design that is shown in Figure 1.1. Due to that, the aim of this project is to

determine the safe working load of the spreader beam based on calculation and

SolidWorks 2011 Simulation method.

3

Figure 1.1: Spreader beam (Company M factory)

1.3 Objectives

The objectives of this project are:

(a) To determine the capacity of an existing spreader beam of unknown potential

using mathematical analysis and SolidWorks 2011 simulation software

analysis.

(b) To identify the safe working load (SWL) value for the spreader beam.

(c) To improve the spreader beam design.

4

1.4 Scope

This project focuses on the method to determine of load capacity for spreader beam

in Company M factory. This project focuses only single spreader beam as shown in

Figure 1.2 that is being used in Company M. The calculation and simulation analysis

of the structure considered in static condition. Two methods that used to determine

the load capacity of the spreader beam are mathematical calculation and FEA

simulation using the SolidWorks 2011 design software.

5

This chapter explains in detail about literature related in this project. The

subjects that are covered are introduced of the spreader beam, current design of

spreader beam, spreader beam design, mathematical analysis, SolidWorks 2011

Simulation software, factor of safety and safe working load.

2.1 Introduction of spreader beam

Spreader beams is below-the-hook lifting device that lift loads with single or

multiple attachment points. A spreader beam usually works with overhead crane used

to assist in the hoisting process for the long or complex object. The basic spreader

beam is shown in Figure 2.1. This arrangement provides two places of attachment to

the object being lifted, thus avoiding the possibility of overstressing. This also allows

for a straight pull on the object rather an oblique pull. This is sometimes important to

minimize unwanted erection stresses or to prevent reversal of stress in certain portion

of the lifted object. Spreader beam can also be used to provide multiple lifting points

on a relatively flexible object. Figure 2.2 shows the spreader beam with two upper

lifting lugs that prevent the objects from tilting. Another element commonly

associated with spreader beams are hooks, shackles and slings. The shackle is used to

connect the lines to the spreader beams that come in various pattern, size and load

capacities that are shown in Figure 2.3. Figure 2.4 shows slings and oblong that used

to suspend the spreader beams from the main hook (David, 2003).

LITERATURE REVIEW

CHAPTER 2

6

Figure 2.1: Basic spreader beam (David, 2003)

Figure 2.2: Spreader beam with two upper lifting lugs (David, 2003)

Figure 2.3: Shackles (David, 2003)

Figure 2.4: Oblong, sling and hook (David, 2003)

7

2.2 Current design of spreader beam

The spreader beams offer the broadest range of Modular Spreader System component

to give the material handling crane operator flexibility to meet lifting requirement

according to the size, shape and weight of an object. Modulift products are designed

following ASME B30.20 Standard that manufactured by Modulift. There are several

types of the Modular Spreader System (Modulift, 2010).

2.2.1 Modular spreader beam

Modular spreader beam is shown in Figure 2.5 system provides the ultimate in

flexibility. Modular spreader beam consists of three parts strut, drop link and end unit

to assemble is is according the size object. (Modulift, 2010)

Figure 2.5: Modular spreader beam (Modulift, 2010).

8

2.2.2 Fixed spreader beam

Fixed spreader beam is shown in Figure 2.6 is the basic design of spreader beam.

This design of spreader beam cannot be adjusted (Modulift, 2010).

Figure 2.6: Fixed spreader beam (Modulift, 2010)

2.2.3 Castellated spreader beam

Castellated spreader beam is shown in Figure 2.7 is a fixed beam with variable

lifting points, which can be easily adjust suitable with an object to be lifted

(Modulift, 2010).

Figure 2.7: Castellated spreader beam (Modulift, 2010)