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Results in Engineering 23 (2024) 102492

Contents lists available at ScienceDirect

Results in Engineering
journal homepage: www.sciencedirect.com/journal/results-in-engineering

A topology optimization design of a crane hook


Vu Duc Hiep a , Nguyen Xuan Quynh b , Tran Thanh Tung a, *
a
Faculty of Engineering Mechanics and Automation, VNU University of Engineering and Technology, Hanoi, Viet Nam
b
School of Mechanical Engineering, Ha Noi University of Science and Technology, Ha Noi, Viet Nam

A R T I C L E I N F O A B S T R A C T

Keywords: The goal of this research was to demonstrate the effectiveness of optimization techniques and test the possibility
Optimization design of using ABS plastic to optimize the existing crane hooks that use these techniques. Based on the optimization
Crane hook results, verification of the modified hook, and structural stability, this optimization reduces the weight of the
3D printing
crane hook while maintaining durability. This study utilized 3D modeling software to optimize the design of an
Topology
existing hook, ensuring both sufficient strength and weight reduction. The research analyzes the results,
concentrating on the stress that falls within the material strength limit. The research begins by utilizing a
maximum of 1 kg of ABS plastic and a 5 kg liftable load. Using topology techniques, the study proposed five
models that meet technical requirements. As a result, the proposed structure is highly economical and optimized
in terms of materials and time, while still ensuring working performance. This work utilizes 3D modeling soft­
ware for optimization design. It was effective to combine 3D printing manufacturing technology with size
considerations. This article serves as a reference for future research and hook design.

1. Introduction printing is a fabrication method that allows for a greater degree of


design freedom when creating complex shapes [9–12].
Structural optimization is the subject of making an assemblage of However, a challenge comes up: when utilizing 3D printing with a
materials sustain loads in the best way. This revolutionary technology specific amount of plastic, what is the most efficient shape for the part?
drastically alters the manufacturing process. It provides numerous op­ If the original quantity of plastic is altered, what will be the resulting
tions for achieving a certain objective based on the designer’s re­ shape while maintaining the initial technical specifications? The goal of
quirements [1–4]. Optimization is an algorithm widely used in many this research was to demonstrate the effectiveness of optimization
fields, such as mechanical design, construction, and architecture [5–8]. techniques and examine the possibility of using ABS plastic to optimize
Traditional structural simulations enable engineers to determine the existing hooks that use these techniques. Based on the results of
whether or not a design can withstand the needed loads. In size opti­ optimizations, modified hooks, and structural stability verifications, this
mization, assumptions about the final structure are made based on an optimization reduces the weight of the rack while maintaining its
initial design. The size optimization method helps to identify good strength. In this study, 3D modeling software is utilized to optimize the
models with the smallest dimensions to provide the lightest structure design of an existing hook with sufficient strength and weight reduction.
possible while maintaining the structure’s load capacity. Topology The results are analyzed with a focus on stress within the material
optimization will find a means to determine the best material distribu­ strength limits. The final prototype was generated with fabrication
tion in a given design domain, removing areas of superfluous material. feasibility in mind. The primary objective of this work was to redesign a
The input condition is load. its ability to reduce the quantity of material hook using the optimization technique to meet a specific technical
used and reorganize it to produce the best construction that can sustain requirement with varying initial conditions.
the imposed loads within the restrictions set. By removing material from
design regions, the topology optimization method produces the lightest
structure while preserving the structure’s load-bearing capacity. This
method is highly compatible with 3D printing technology. 3D printing
presents opportunities to build unique and complex structures. 3D

* Corresponding author.
E-mail address: [email protected] (T.T. Tung).

https://doi.org/10.1016/j.rineng.2024.102492
Received 1 March 2024; Received in revised form 30 May 2024; Accepted 30 June 2024
Available online 2 July 2024
2590-1230/© 2024 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-
nc-nd/4.0/).
V.D. Hiep et al. Results in Engineering 23 (2024) 102492

the critical section. The scale unit in Fig. 1 is millimeters.


When the crane hook lifts a maximum weight of 5 kg, the assumption
it follows a uniform normal distribution within ±45◦ around the edge of
the hook mouth [13–15].
The parameters in the safety factor (F.O.S) of the equation include σ
m is the failure stress of the crane hook, σ h is the allowable stress of the
crane hook. The formula to calculate the safety factor as follows:
σh
Max. F.O.S = (20)
σm
A stress concentration, or stress riser, is a localized area within a
component where the stress level is notably higher compared to its
neighboring regions. Stress concentrations arise from irregularities in
the shape or material of a component, leading to a disruption in the flow
of stress.
Fig. 2 compares the stress distribution between an abruptly changing
Fig. 1. The layout of the inner point and boundary nodes.
shape and a gradually changing shape. For the stress distribution of an
abruptly changed shape, it shows that the stress distribution is concen­
2. Materials and methods trated at the position where the shape is suddenly changed. For shapes
that change gradually, it shows that the stress is less concentrated in the
2.1. The analysis of lifting hook areas where the shape changes.

The mass of the crane hook is 5 kg. According to the ISO-7597-2013


2.2. Crane hook design
crane hook standard, we have dimensions for the crane hook: the
diameter of the shaft holes is 14 mm. The maximum radius of the mouth
Three main factors are considered when designing a crane hook:
is 24 mm. The maximum eccentric cylindrical radius of the hook body is
material, hook cross-section, and hook radius. During operation, the
60 mm. The hook is made of ABS material. When BIRKPM is applied to
hook must be subjected to bending stress and normal stress. However,
examine plane stress issues, there are 150 nodes irregularly placed on
bending stress is more dominant during the lifting process, leading to
the inner and outer boundaries, along with 20 inner points distributed in
hook failure. Crack initiation in hooks occurs at points of high stress

Fig. 2. Stress distribution.[16]

Fig. 3. Crane hook dimensions are according to actual standards.

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V.D. Hiep et al. Results in Engineering 23 (2024) 102492

Fig. 6. Initial loading.

concentration and is the leading cause of hook failure. Crane hooks


require regular visual inspection of the hooks based on the material and
type of hook operation (including deformation). This study has analyzed
hook stress under different loading conditions, simulating stress flow to
distribute areas with high stress concentration, where damage occurs,
and areas with lower stress concentration, where damage is less likely to
occur. When conducting analysis and design research on crane hooks, it
is possible to reduce production costs and apply finite element analysis
Fig. 4. The cross-section. methods compatible with optimization design methods.
In Fig. 3, it is shown that all the parameters of the crane hook are
described and the standard dimensions (scales) are listed. The high and
Table 1 low stress concentration zones of the cross section are designated, which
Maximum size of the crane hook. are the modification areas of the crane hook to obtain better results on
Dimension Maximum Value (mm) the maximum weight and stress of the crane hook.
Bs 45 The crane hook is modeled as a curved beam, and all stress calcu­
D1 48 lations are performed accordingly. Curved beam geometry experiences
D2 14 two different stresses. The first is the bending stress carried by the
M 14
curved section of the beam, and the second is the axial part that is
H1 43.2
H2 43.2 subjected to direct stress. Since the cross-section in this case is square,
L 127 one of the two cross-sections at the maximum level will experience the
Zs 39.9 maximum stress (the outer surface or the inner surface) (Fig. 4).
M = Bending Moment.
A = Area of trapazoidal cross section
r0 = radius of neutral axis
rg = center of gravity
e = e centricity i.e., distance of the centroid from neutral axis
y = distance of the neutral axis from fibre
y1 = distance of neutral axis from innermost fibre
y2 = distance of neutral axis from outermost fibre.
The Winkler-Bach formula is utilized to calculate bending stress in
the following approach [16].
( ) ( )
M y
σb = − x (21)
Axe r0 − y
According to the DIN15401 crane hook standard, we have the
following dimensions of the crane hook:
34.0 ≤ Bs ≤ 45.
30.0 ≤ D1 ≤ 48.0.
10.0 ≤ D2 ≤ 14.0.
10.0 ≤ M ≤ 14.0.
27.0 ≤ H1 ≤ 43.2.
27.0 ≤ H2 ≤ 43.2.
100.0 ≤ L ≤ 127.0.
35.0 ≤ Zs ≤ 39.9.
Bs > Zs.
Fig. 5. CAD model. Zs > C.

3
V.D. Hiep et al. Results in Engineering 23 (2024) 102492

Table 2 2.4. Size optimization design


Load condition.
Force Value To set up an optimization problem, an objective function, constraint
functions, and design variables must be specified. GEKKO is a Python
F 50 [N]
library designed to solve optimization, simulation, and control prob­
lems. It supports solving continuous and discrete optimization problems.
GEKKO is capable of solving problems with linear and nonlinear con­
Table 3 straints and controls.
Engineering material properties for the ABS materials.
The hook has a rectangular cross-section of width b (minimum 27
Mass Density 1050 [kg/m3] mm) and height h. Optimized crane hook design to minimize hook
Young’s Modulus 2000 [MPa] weight. The outer radius of the hook is ro and the inner radius is ri with a
Poisson’s Ratio 0.4 minimum inner diameter of 24 mm. Height is the difference between the
Yield Strength 40[MPa] outer radius and the inner radius h = ro-ri. The bending moment is M = F
x R with a force F of 50 N (5 kg for static load). The center radius is R and
Wn ≤ Wo. the neutral axis radius is rn [22].
Bs, D1, D2, M, H1, H2, L, Os, Wn, Wo > 0. h
This constraint condition is based on the actual working conditions rn = ( ) (22)
of the crane hook: working with lifting conditions weighing 5 kg and the ln rr0i
surrounding space of the crane hook is allowed to have the maximum
value as shown in Table 1. With these conditions: Bs > Zs, Zs > C, Wn ≤ The difference between the centroid radius and the neutral axis
Wo, Bs, D1, D2, M, H1, H2, L, Os, Wn, Wo > 0.

2.3. Numerical model

As illustrated in Fig. 5, a numerical model of the hook was built in the


3D modeling software.
Crane hooks are subjected to load conditions as shown in Fig. 6 and
Table 2. These initial loading conditions are derived from the indicated
working of the component in previous research [17–20].
In this study, the material used for the hook is ABS plastic. There are
lots of advantages to ABS plastic, ranging from its affordable production
costs to its robustness and aesthetic structure. Its resistance to repeated
heating and cooling makes it an excellent candidate for recycling. ABS is
flexible in terms of color and surface texture options, and it can be
designed and built to dramatically increase the standard of quality. It is
light-weight and applicable to a wide variety of uses. Finally, ABS plastic
has excellent impact resistance and can effectively and reliably absorb
shocks. All the considered parts were made of ABS plastic, whose ma­
terial properties are listed in Table 3.
From the 3D modeling software results, it shows that with the
tolerance limit of ABS material being 40 MPa, the maximum stress
arising is 2.14 MPa, the safety factor is 18.7, and it weighs 412 g, as
shown in Fig. 7. From the results of the finite element method survey and
the crane hook design, it can hang a 5 kg object in accordance with the
Fig. 8. Analysis of the crane hook.
standard hook and is determined to have the largest size.

Fig. 7. Maximum mass and stress of the initial crane hook.

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V.D. Hiep et al. Results in Engineering 23 (2024) 102492

Table 4
Sizes of crane hooks after applying GEKKO.
Bs (mm) D1 (mm) D2 (mm) M (mm) H1 (mm) H2 (mm) L (mm) Zs (mm) Mass (g) Stress (Mpa) F.O.S

37.7 38 14 14 40.6 40.6 122 36.8 412 1.73 23.1

Fig. 9. Mass of the models after optimal design.

radius is e. The stress at point A is [22]: properties, and model assumptions. It is given a design constraint on the
theoretical design capacity to overcome uncertain parameters (such as
M(r0 − rn )
σA = (23) manufacturing process and material strength).
b h e r0
From the above analysis results,as shown in the Fig. 12the type F
The stress at point B is [22]: model will be selected because model F has a stress of 1.73 and a F.O.S.
of 23.1.
M(rn − ri )
σB = (24)
b h e ri
3. Topology optimization design theory
With the input conditions of inner radius ri = 24 mm, width b = 27 mm,
√̅̅̅ C √̅̅̅̅̅̅ The goal of topology optimization is to identify the ideal material
Zs = 1.5C = 1.4*27 = 37,8 mm, H1 = H2 = (5.4 P + 10 ) = (5,4 50 +
27
distribution inside a predetermined area [13]. This is achieved by
10) = 40.6 mm.
minimizing (or maximizing), subject to constraints and boundary con­
Fig. 8 shows the input conditions and the inner radius, outer radius, ditions, the structural attributes. To identify which components will
width and height of the crane hook. contain material and which will be voids, the design domain is dis­
Table 4 shows the dimensions of the crane hook after applying cretized into finite elements using one of several optimization tech­
GEKKO: the smallest volume is V = 392403.3348 mm3, r0 = 60 mm, ri = niques [14]. In contrast, shape optimization seeks to identify the best
24 mm, b = 30 mm. shape for a domain with a specified topology; as a result, the design
Similar to above, we have models after size optimization based on variable is the boundary of the design domain. Ideally, the topology
the GEKKO algorithm as shown in Fig. 9. optimization results should return only elements with material or only
Figs. 9 and 10 show mass and stress models based on dimensional elements with voids. It is known as a “black-and-white" or “0–1″ prob­
constraints. lem. However, using this strategy will produce 2 N (where N is the
Table 5 shows the dimensions of the crane hooks after modification. number of components) that can blend solid and empty elements,
Figs. 11 and 12 show the mass, stress, and safety factor of the models making it impossible for most models to solve. Instead, to make the
after size modification. solution closer to the discrete values 0–1, a continuous variable is used
After adjusting the appropriate size, crane hooks from type A to type in place of the integer variable (0 or 1), and a penalty function is added.
G are weighted less. Type B has the lowest weight of 237.1 g, and type F This process is called relaxation of the design domain Ω, as shown in the
has the highest safety factor of 23.1. Fig. 13
The safety factor increases safety and reduces the risk of structural Within a given design area, for specified loads, boundary cases,
damage. Safety factors are the most important regarding equipment manufacturing constraints, and performance requirements, the SIMP
safety. Safety factors are used when designing structures. In reality, approach forecasts the ideal material distribution. According to Dassault
there are some uncertainties about the applied forces, material

5
V.D. Hiep et al. Results in Engineering 23 (2024) 102492

Fig. 10. Stress analysis of models after optimal design.

Table 5
Shows the revised dimensions of the crane hook.
Type Bs (mm) D1 (mm) D2 (mm) M (mm) H1 (mm) H2 (mm) L (mm) Zs (mm) Mass (g) Stress (Mpa) F.O.S

A 41.2 43 14 14 42.7 42.7 124.5 34.4 319.2 2.1 19


B 43 36 14 14 30.1 30.1 125.6 33.5 237.1 2.38 16.8
C 42.4 48 14 14 37.1 37.1 127 39.4 285.3 2.5 16
D 38.2 40 14 14 37.1 37.1 123 35.6 270.1 2 20
E 43.4 48 14 14 33.1 33.1 127 39.4 263.3 2.85 14
F 37.7 38 14 14 40.6 40.6 122 36.8 289.8 1.73 23.1
G 36.3 34 14 14 40.1 40.1 120 32.4 277.9 1.78 22.5

Fig. 11. Mass of models.

6
V.D. Hiep et al. Results in Engineering 23 (2024) 102492

Fig. 12. Stress and safety factor of the models.

Fig. 13. Solid and empty elements.

Fig. 15. Design and non-design areas.

elements (referred to as porous elements): ρmin is the lowest permitted


relative density value for elements with empty spaces larger than zero.”
Any densities between it and 0 are converted into voids automatically,
therefore p = 0. Less mistakes in the finite element analysis are guar­
anteed by this density value.
The Young’s modulus of the material at each element can change
constantly because the relative material density varies continuously for
each element. Each element, e, has a relationship between the assigned
isotropic material’s assigned Youngs modulus and the proportional
material density factor, pe, E0, according to:
E\(ρe ) = ρpe E0 (25)

where:
E(ρe ) = local stress-strain relations/stiffness tensor
ρe = the element density
p = the penalization factor.
E0 = Youngs modulus of assigned isotropic material.
Fig. 14. The relative stiffness varies depending on the applied penaliza­ The impact of elements with intermediate densities on the overall
tion factor. stiffness is lessened when the penalty factor p is used. The penalty factor
optimizes the response to elements that are either solid or fragile (=1) or
Systémes, “the binary, on-off aspect of the issue is avoided by the voids (=0). For materials where v = 0.5 is the poison ratio, It is advised
addition of a continuous relative density distribution function. The to employ a p = 3 penalty.
allocated relative density for each element can range from a minimum
value of ρmin to 1, allowing the assignment of intermediate densities for

7
V.D. Hiep et al. Results in Engineering 23 (2024) 102492

Fig. 16. The simulation results of the design space.

Fig. 17. (a) 22 % weight reduction (b) 30 % weight reduction (c) 50 % weight reduction (d) 70 % weight reduction.

3.1. Topology optimization design process machinery, containers, and structural beams. Hooks are rated for loads
of a specific size and kind, and they are available in a variety of forms to
This procedure uses the Topology Optimization approach to meet various demands, just like other crane parts. Use only high-quality
restructure an existing hook’s structure [17–21]. A crane hook is a point crane hooks; otherwise, you risk damaging the crane or losing the load.
of connection designed to connect with ropes and chains attached to Crane hooks must therefore be constructed and manufactured to

8
V.D. Hiep et al. Results in Engineering 23 (2024) 102492

account for production conditions (see Fig. 14).


The initial stage in topology optimization is choosing the optimiza­
tion type and identifying design and non-design regions, as shown in
Fig. 15. With the exception of regions used for assembly and direct
loading, such as the hole region and load hook, the design areas for the
complete hook are chosen.
The next stage of topology optimization is to define the goal function.
The goal of all topological optimizations is to maximize the stiffness of
the hook. To do this, the mass target is utilized to calculate how much
material should be retained. According to Fig. 16, the mass objective is
expressed as a percentage of the entire volume of the design space.
Weight is chosen as the mass goal. Weight makes up 22 %,30 %, 50
%, and 70 % of the entire design component. Fig. 17 illustrates a pre­
liminary description of the ideal design’s structure in an effort to reduce
weight. A desktop personal computer with Cores i5, 1.6 GHz, and 4 GB
Fig. 18. Set of frame nodes connected to frame segments.
of RAM processed data for a total of around 6 h.
Process results after optimization [21]: Each cross-section plane
passes through a skeletal node, called the positioning node, and its
normal coincides with the direction vector associated with this node as
illustrated in Fig. 18.
Fig. 18 shows the nodes of the frame connected together to form the
frame of the model. For a given cross-section, all interpolation points lie
in the same plane, which is normal to the direction vector, as shown in
Fig. 19. Interpolation points and curves are calculated between branch
limits based on user input to determine the number of equally spaced
cross-sections. At limit nodes, a minimum of two cross-sections per
branch must be calculated.
Fig. 20 show the reconstructed CAD model based on the analysis of
the model frame’s nodes.
When performing analysis of proposed optimization models, it is
important to compare topology optimization results with each other. To
Fig. 19. Direction vector and cross-sectional plane [17]. confirm the stability of the structure, optimization analysis was
performed.
Fig. 21 shows that the high stress areas of all models are optimized.
constantly perform at their highest level. With this optimization, the
High stresses are concentrated in areas on the inner surface of the hook
structure’s strength will be ensured while the weight is reduced and
close to the inner curved linear surface due to concentrated stress. The
extra material is removed.
greatest stress is concentrated near the inner surface of the hook.
The comparison between models in terms of weight and safety factor
3.2. Topology optimization design is summarized in Table 6.
Fig. 22 is a chart showing the stress and mass for each crane hook
An objective function, constraint functions, and design variables model after processing the rough model to ease the manufacturing
must all be stated when setting up an optimization problem. The goal of process and improve manufacturing accuracy.
this study was to reduce weight while staying within the constraints of The safety factor varies depending on the situation. The systems are
forces and immovable objects, such as holes with a 14-mm diameter. By intentionally designed to have a higher safety factor than is necessary for
considering the load boundary condition and the portion of the structure a typical installation. This increases performance even under harsh
that doesn’t change, the 3D modeling software program optimizes the conditions such as emergency situations, increased loads, overuse, or
number of iterations of the structure. The design is altered during each deterioration due to wear and tear. The safety factor of model (a) is the
iteration step based on the results collected, with modifications made to highest, and the safety factor of model (d) is the lowest.

Fig. 20. Reconstructed CAD model.

9
V.D. Hiep et al. Results in Engineering 23 (2024) 102492

Fig. 21. Stress simulation test.

4. Result and discussion


Table 6
Design comparison. Fig. 24 shows the test results of the reconstructed structures; The
Model Mass (kg) Stress (MPa) Stress limit of the material (MPa) F.O.S maximum stress of the structures is within the stress limit of the material
(less than the allowable stress of 40 MPa).
a 0.33 1.7 40 23.5
b 0.31 1.95 40 20.5 Figs. 25 and 26 shows the weight of the models: compared to the
c 0.21 2.7 40 14.8 original, the proposed structures are 22 %, 30 %, 50 %, 70 % lighter,
d 0.13 3.7 40 10.8 412 g, 313 g, 309 g, 209 g, 157 g respectively. The volume also
decreased significantly (from 392403,3348 mm3 to 298360,3347 mm3,
294757,9395 mm3, 199213,0306 mm3, 149523,4263 mm3
Usually, the initial optimal structure is a rather complex structure,
respectively).
making the manufacturing process difficult. Therefore, the structure had
As illustrated in Fig. 27, a 3D-printed prototype was eventually
to be modified to make it easier to fabricate. High-pressure areas are
produced at the Faculty of Engineering Mechanics and Automation,
constructed with additional materials for a longer life. After the struc­
VNU University of Engineering and Technology, Vietnam. The printing
tural optimization phase, the next step is to refine the design to facilitate
time was roughly 6 h, which was significantly less than the prototype’s
the fabrication process. This process deeply examines the proposed
11 h. Results show that the design is workable and can be successfully
structure to redesign aspects of the design that are having difficulty in
produced using 3D printing technology. With respect to the design space
manufacturing. When refining the shape of the part, be careful not to
and the applied pressures, weight and stress levels have successfully
change the shape suddenly to avoid causing stress concentration. Fig. 23
decreased. Fig. 28 shows that the redesigned design still functions as
depicts the ideal structure in its final form. The redesigned model is then
intended. As a result, the suggested construction is very cost-effective,
tested with the same loads and boundary conditions as the original
time- and material-efficient, and nevertheless ensures functioning
design.
performance.

Fig. 22. Stress and mass for each crane hook model.

10
V.D. Hiep et al. Results in Engineering 23 (2024) 102492

Fig. 23. Proposed design model.

Fig. 24. Stress simulation analysis.

Fig. 25. Mass of crane hooks.

11
V.D. Hiep et al. Results in Engineering 23 (2024) 102492

Fig. 26. Mass change between models.

Fig. 27. New designed crane hook manufactured using 3D printing method.

Fig. 28. Comparison between the original design hook and the new design.

5. Conclusion algorithm. The article presents four new models based on the original
model, each with a reduced volume of 22 %, 30 %, 50 %, and 70 %
The article presents a method for optimizing the hook using opti­ respectively. These models maintain their ability to function effectively.
mization using 3D modeling software combined with the GEKKO The results indicate the design is feasible and can be manufactured using

12
V.D. Hiep et al. Results in Engineering 23 (2024) 102492

3D printing technology without trouble. Therefore, the proposed [6] C. Li, H. Lei, Z. Zhang, X. Zhang, H. Zhou, P. Wang, D. Fang, Architecture design of
periodic truss-lattice cells for additive manufacturing, Addit. Manuf. 34 (2020)
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software for size optimization. Combining the 3D printing technology topology optimization and path planning for composites manufactured by fiber
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