Abstract:
Tower cranes are widely utilized in heavy industries and construction sites to lift and carry heavy
materials. So, to save life, time, and cost, the right design of the crane has an important role within
the safe operation of construction sites. A crane is subjected to continuous loading and unloading
condition that exposes the crane components to fatigue failure, among others, the crane hook and
causes serious accidents because most construction sites are very confined and shut to the general
public, tower crane accidents not only hazard to workers in construction sites but also pedestrians
within the vicinity. The main objective of this study is to develop the conceptual framework of design
optimization and then apply topology optimization designxplorer to enhance the strength and
endurance requirements of the crane hook. In order to fulfilstrength and endurance requirements on
the tower crane hook, optimization is a useful tool to predict an optimal design in the early phases of
the design process. In this thesis work, a completed design of a hook constructed and topology and
shape optimization has been conducted on the crane hook. Topology optimization is an optimization
technique that employs mathematical tools to optimize material distribution in a crane hook to be
designed. So topology optimization is conducted on the crane hook without sacrificing strength and
durability. The topology optimization conducted as part of this thesis reduced the mass by 6.685%
(mass reduction, of crane hook from 15.75 kg to 13.678 kg). Simulation of the hook was done using
the topological approach, where the model was created, and then meshing was done and FEA analysis
(ANSYS 19.2) was carried out. The core part of the work done in this thesis includes Parameterized
finite element analysis, designxplorer, and Topology optimization. Designxplorer is a simulation tool
or module in ANSYS workbench that is implemented using surface response sensitivity and design
of the experiment to define the input and output relationship. These input parameters decide the
surface of the crane hook and the output relation minimum factory of safety and maximum equivalent
stress decide the life and strength of crane hook. The main contribution of this study is to investigate
the possible methods of optimizing the strength and endurance required of the crane hook.
