Apuva 4
Apuva 4
Results in Engineering
journal homepage: www.sciencedirect.com/journal/results-in-engineering
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.
* 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
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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
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
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V.D. Hiep et al. Results in Engineering 23 (2024) 102492
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
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V.D. Hiep et al. Results in Engineering 23 (2024) 102492
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
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V.D. Hiep et al. Results in Engineering 23 (2024) 102492
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
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V.D. Hiep et al. Results in Engineering 23 (2024) 102492
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Fig. 22. Stress and mass for each crane hook model.
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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
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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)
structure is highly economical, optimized in terms of materials and time,
101172.
and still ensures working performance. This work utilizes 3D modeling [7] Maximilian Eckrich, Peter A. Arrabiyeh, Anna M. Dlugaj, David May, Structural
software for size optimization. Combining the 3D printing technology topology optimization and path planning for composites manufactured by fiber
used for manufacturing with size proved to be effective. This article placement technologies, Compos. Struct. 289 (2022).
[8] K. Mehl, S. Schmeer, N. Motsch-Eichmann, P. Bauer, I. Müller, J. Hausmann,
provides a reference for further related research and hook design. Structural optimization of locally continuous fiber-reinforcements for short fiber-
reinforced plastics, J Compos Sci 5 (5) (2021) 118.
[9] T.T. Tung, N.X. Quynh, T.V. Minh, Design and fabrication of a gripper PROPOTYPE
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editing, Methodology, Conceptualization. [11] Jihong Zhu, Z.H.O.U. Han, Chuang Wang, Lu Zhou, Shangqin Yuan,
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Declaration of competing interest [12] Tran Thanh Tung, Nguyen Xuan Quynh, Tran Vu Minh, A prototype of auto
badminton training robot, Results in Engineering 13 (March 2022) 100344.
[13] L. Rao, H. Chen, The technique of the immersed boundary method: application to
The authors declare no conflict of interest. solving shape optimization problem, J. Appl. Math. Phys. 5 (2017) 329–340.
[14] D. Webb, W. Alobaidi, E. Sandgren, Structural design via genetic optimization,
Data availability Mod. Mech. Eng. 7 (2017) 73–90.
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[17] N. Puodziuniene Narvydas, Circumferential Stress Concentration Factors at the
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