Analysis of Traverse Beam used for the Expansion of Steel ...onlinepresent.org/proceedings/vol147_2017/69.pdf · which is used in the steel melt shop to charge molten pig ... Galambos

Analysis of Traverse Beam used for the Expansion of

Steel Plant

D. Ajay Kumar1, Dr. K. S. Raghu Ram2 and Dr. B. Avinash Ben2

1Assistant Professor,

Department of Mechanical Engineering,

Vignan’s Institute of Information Technology, Visakhapatnam. 2 Associate Professor,

Department of Mechanical Engineering,

Vignan’s Institute of Information Technology,

[email protected]

Abstract. The Von Mises stress and principal stress calculation using Finite

Element analysis and comparison of the simulated results with the analytical

method is the aim of the present research work. Finalization of the dimensions

as per the requirement is considered. Analytical results are very closer to the

simulated results and is adopted for the application in real time and there were

no problems of the application of the designed beam. The beam assembly is

tested under full load and is successfully operating since many years.

Keywords: cross section of the traverse beam – finite element analysis –

analytical calculations- safe application for the use of lifting heavy loads.

1 Introduction

The expansion of tonnage transport of load and National Steel policy 124 MT load

carry is a hard task to carry. This expansion drive would be challenging to bring its

expanded capacity on stream. As it is known, there are several beam theories to

describe behavior of beam-type structures. The oldest and the well-known beam

theory is the Euler–Bernoulli beam theory (EBT) in which straight lines perpendicular

to the mid-plane before bending remain straight and perpendicular to the mid-plane

after bending. As a result of this assumption, traverse shear strain is neglected.

1.1 Scope of the present work

In the present work, a theoretical analysis is carried out for the design of a traverse

beam used in steel melting shop in steel plants. The traverse beam is fixed to a crane,

which is used in the steel melt shop to charge molten pig iron in a ladle to the steel

converter. The need for fixing the traverse beam to the crane arises due to the fact that

crane with a larger distance between the arms (4600 mm) is used to handle a smaller

Advanced Science and Technology Letters Vol.147 (SMART DSC-2017), pp.499-505

http://dx.doi.org/10.14257/astl.2017.147.69

ISSN: 2287-1233 ASTL Copyright © 2017 SERSC

ladle, whose width is 4300 mm. The existing old ladles are handled by the new

cranes, where the traverse beam is required for the crane.

1.2 Need for Traverse Beam

The molten pig iron is carried through ladles and poured into the LD converters.

Overhead cranes are used for carrying ladles containing molten metal. The old ladles

in steel plant have a center distance of 4300 mm. SMS-II uses new overhead cranes

with center distance of 4600mm.Thus the width of the crane (4600mm) is more than

that of the ladle (4300mm).Since the crane and ladle must be synchronous, a traverse

beam is designed, such that the ladle can be handled by the crane. By designing the

traverse beam one can eliminate making of new ladles to suit to the new cranes which

have 4600mm of center-to-center distance. This results in considerable savings in

terms of time and money.

The complete drawing details are taken from the above drawing. The traverse beam

drawing is again considered for design consideration. The design details are given in

the figure 3 with part details.

Fig. 1. Schematic details of the

Traverse Beam Assembly

Fig. 2. Showing the drawing details of

the complete crane assembly

Advanced Science and Technology Letters Vol.147 (SMART DSC-2017)

500 Copyright © 2017 SERSC

Fig. 3. Showing the details of the traverse beam with part details.

1.3 Fabrication of Traverse Beam Assembly

The traverse beam is attached to the crane arms. Four hook shackles are inserted in the

slots of the traverse beam, and are welded to it. The top parts of the hook shackles are

fixed to the crane body by means of two pins. Thus the traverse beam is attached to

the crane, and hangs below the crane. The length of the traverse beam is 4600 mm.

The crane hooks are fixed to the bottom parts of the hook shackles by means of

another two pins. A smaller distance of 4300 mm is maintained between the crane

hooks by means of the hook shackles and pins.

Two I-sections of mild steel of 6605 mm are chosen for the traverse beam. Slots

are cut in the I-sections to attach the hook shackles. Thus the traverse beam is attached

to the crane arms and the crane hooks are attached to the beam. The ladle of 4300 mm

can be hanged from the crane hooks now. The ladle containing molten pig iron

weighs about 250 tons.

The traverse beam is subjected to large principal stresses at the pins, hook shackles

and crane hooks. It is desired to assess the strength of the traverse beam assembly

theoretically before it is put to actual use. Hence a theoretical analysis is carried out

for the traverse beam assembly. The theoretical analysis, which is carried out by using

CATIA and ANSYS software packages.


Copyright © 2017 SERSC 501

1.4 Geometrical model of Traverse Beam Assembly

The geometrical model of the traverse beam assembly is drawn in Catia-v5 software

as per the dimensions given in the 2-D drawing, which is presented in the above

figures. The CATIA model of the traverse beam along with the welded plates is

shown in the figure. The specifications of different components of the assembly such

as the size, material, and weight are given in the table1.

Fig. 4. Showing the design of the traverse beam using CATIA software.

Table 1. Showing the components of traverse beam.

Part

No Name of the item and Size Material QTY

Total

Weight(Kgf)

1.1 UB 610X220X113 STEEL 2 1493

1.2 PLATE 548X500X20THK STEEL 9 380

1.3 HOOK SHACKLE(SUBASSLY) STEEL 4 2680

1.4 PLATE 572X109X20THK STEEL 10 97.8

1.5 PLATE 665X288X20THK STEEL 4 112.8





ASSUMPTIONS

In order to compare the value of maximum principal stress in the XY- direction of

traverse beam obtained from ANSYS with a mathematical approach, the following

assumptions were made:

The geometry of the traverse beam is compared with a simply supported

beam of 4600mm.

Two point loads of each 125tons are taken centre to centre 4300mm of

the simply supported beam.

The constraints are assumed as reaction forces each of them equal to

1226KN.

Anticlockwise moments are taken positive and Clockwise moments are

taken negative.

Calculations for Principle Stress:

The principle stress is given by the formula:- 𝑀

𝐼𝑋𝑋=

σ

𝑌

Where

M= Bending moment, N-mm.

I = Area moment of inertia about neutral axis, mm4.

σ = principal stress in XY – direction, N/mm2.

Y =distance of the neutral axis from the top, mm.

For I-section beam

Fig. 5. Showing the Cross section area Traverse beam



Let,

RA = reaction at A

RB = reaction at B

Taking moments about the point ‘B’

RA x 4600 = 1226250 x 4450 +

1226250 x 150

RA = 1226 KN

Now taking moments about the point

‘A’

RB x 4600 = 1226250 x 4450 +

1226250 x 150

RB = 1226 KN

Bending moment M = 183.9 x 106 N-

mm

𝐘 = 315.8 mm

𝐼𝑋𝑋 = 𝐼𝑋𝑋(𝑈) + 𝐼𝑋𝑋(𝑃𝐿𝐴𝑇𝐸)

𝐼𝑋𝑋(𝑈)= 2 x 87320 x 104 = 1746 x

106 mm4

𝐼𝑋𝑋(𝑃𝐿𝐴𝑇𝐸) = 2 x [ 700𝑋123

12 +

(700 x 12 x (303.8)2 ) ] = 1550 x

106mm4

𝐼𝑋𝑋 = 3297.14 x 106 mm4

σ = principal stress in XY –

direction (in N/mm2)

σ = 𝑀𝐼𝑋𝑋𝑌

𝛔 = 17.62 N/mm2

4 Conclusions

1. A traverse beam carrying a load of 250 tons has been designed, fabricated,

tested and put into service in SMS-II Steel Plant.

2. Theoretical analysis has been carried out with the aid of CATIA and ANSYS

software to predict the stress exerted on the traverse beam. This theoretical

analysis was carried out before applying the actual load on the crane with

traverse beam.

3. Since the payload is hot molten metal and any failure of the components could

be disastrous in terms of human life, injury, and other economic costs, a factor

of safety of more than 4 was used in the design process.

4. Manual calculations of von Mises and principal stresses were also carried out.

These values compare fairly well with the ANSYS results for all components.

182 MPa with manual calculation vs. 169 MPa of ANSYS results



5. Material selection was done from a set of available materials and choice was

made based on that material which exceeded the minimum stipulated factor of

safety.

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Analysis of Traverse Beam used for the Expansion of Steel ...onlinepresent.org/proceedings/vol147_2017/69.pdf · which is used in the steel melt shop to charge molten pig ... Galambos