Costs

As according to the calculations, the total volume of HSLA steel used is 18.084*10^(-3) m^3 and cost of 1 m^3 is £ 35277.77.

So, therefore the cost of the total HSLA steel to be used is = 35277.77*18.084*10^(-3) GBP

= £637.96

Cost of the manufacturing of special I-Beam = £100

Cost of 16 nuts and 16 bolts is as follows;

Cost of A2 stainless steel M12*110mm bolts = £ 19.50

Cost of A2 stainless steel M12 hex nuts = £ 2.70

Cost of chain hoist = £ 150.49

Cost of rollers = £ 48.69

Cost of rubber sphere = £20.99

The total cost of crane comes out to be £ 980.33. As this is the cost of single K-crane, the cost per crane can be brought down depending on the number of cranes ordered.

The selling price of this crane is £1349.99 giving us the profit of approximately £370 per crane. Assuming, if we get the order for 100 cranes, we can easily make profit more than £37,000.

Total Volume of Steel Used

1.) Volume of the top sheet = 5*0.08*0.005m^3 = 0.002 m^3
Volume of the both sheets = 2 * 0.002 m^3 = 0.004 m^3

Volume of vertical sheet = 10*10^(-3)*190*10^(-3)*5 = 0.0095m^3
Total volume of the top beam = Sum of the volumes two parallel sheets and vertical sheet
= (9.5+4)*10^(-3) m^3 = 13.5 * 10^(-3) m^3

2.) Now, In this part we would calculate the volume of the rectangular bars,
Height of the bar = 1.06 m
Breadth of the bar = 50 mm
width of the bar = 50 mm
, therefore the volume of this bar = 1.06*0.05*0.05 m^3
= 2.65 * 10^(-3) m^3
Since this bar is hollow from inside, we would calculate the volume of unoccupied space
= 1.06*0.04*0.04 m^3 ( the thickness is 5 mm)
= 1.69*10^(-3) m^3

The original volume occupied by HSLA steel = (2.65-1.69)*10^(-3) m^3
= 0.96*10^(-3) m^3
As the total no. of bars used in this gantry crane is 2, so multiplying the result by 2, we get
= 2*0.96 *10^(-3) m^3 = 1.92*10^(-3)m^3


3.) Here we will determine the amount of material used i.e. the volume of the four hollow legs used in this crane.
Height of the rectangular bar = 0.74m
Width of the bar = 50mm
breadth of the bar = 50mm
Volume = 0.74*0.05*0.05 m^3
= 1.85 * 10^(-3) m^3
Since the thickness of the steel is 5 mm, therefore in this case the breadth and width becomes 40 mm.
The volume of the space with these dimension = 0.74*0.04*0.04m^3
= 1.184*10^(-3) m^3
The volume of the steel used in this bar = (1.85-1.184)*10^(-3) m^3
= 0.666*10^(-3) m^3
Now, the number of these bar legs used = 4
The total volume of the HSLA steel used = 4*0.666*10(-3)m^3
=2.664*10^(-3) m^3

4.) Volume of the spheres used = 4*4/3*3.14*((0.15/2)^3) m^3
= 4*1.767*10^(-3) m^3
= 7.068*10^(-3) m^3
The material used for these spherical balls is volcanic rubber which would give the crane extra stability on uneven ground.

According to these calculations, the total volume of the HSLA steel used = 18.084*10^(-3) m^3

Main Beam Final Calculations

These calculations show the final dimensions for the main beam cross section that we settled on. The I value is finalised and the maximum stress and maximum deflection are calculated to be comfortably below the threshold that we decided.

Weight of Main Beam

An estimated weight of 105.3kg is established for our main beam. We consider this to be a weight that can be carried by multiple people over 100m and carried by vehicle.

A further consideration is that the ends of the beam could be made smaller as shown in the diagram at the top of the picture. As most of the stress and weight is centred in the middle of the beam, the ends wouldn't need to be as thick and weight of the beam could be minimised in this way.

Main Beam Further Calculations

These calculations provide different values of I by using different dimensions for the cross-section.

Lifting Chain

Lifting chain is designed for use with hoists, cranes, winches, and other material handling equipment. It is also used in rigging slings and for lashing. There are two standard grades for lifting chain: grade 80 lifting chain and grade 100 lifting chain
We will be using grade 100 lifting chain which is made of alloyed steel and is hardened and tempered for superior durability and fatigue resistance.Grade 100 lifting chain is made of Herc-Alloy 800, a heat-treated alloy with very high strength. 'When working with lifting chain, working load limit and rated capacity vary with the angle of use and the number of lifting chain used in a sling. For example, a single 5.5 mm lifting chain may be rated for 2100 lbs. at 90 degrees. A double 5.5 mm lifting chain may be rated for 60, 45, or 30 degree use with working loads of 3600, 3000, and 2100 lbs. respectively.'

Nuts and Bolts

The nuts and bolts which we will use in the manufacturing of our crane will be made of stainless steel. The nuts as well as the bolts will be coated with zinc to prevent corrosion.Stainless steel is a type of metal alloy. The components of stainless steel are iron, chromium, carbon, nickel, molybdenum and small quantities of other metals. These components are present in varied proportion in different varieties of steels. In stainless steel, the chromium content should not be less than 11 percent. The high content of chromium present in stainless steel is responsible for corrosion resistant property. In order to achieve higher resistance to corrosion nickel is added. Iron is the primary component of steel but it resists oxidation because the chromium present in the steel reacts with oxygen to form chromium oxide. It adheres to the surface of the stainless steel in the form of a tough, passive coating. In case the surface of this layer is damaged due to some chemical or mechanical effect, the chromium oxide formed, is capable of mending the damage. The strength and toughness of steel is because of the carbon present in it. With the increase in the carbon content the toughness of steel also increases