Durham College

Hook
Design
Project
Aaron Leung, Blake Smith, Kevin Ali, Jeroen Van
Leeuwen

Initial Hook Design:

Our initial design involved getting a general shape and removing some unnecessary
weight, which happened to be the open end hook tip, and creating somewhat of a T
shape on the bending portion of the hook. Pinned end had been left alone at this point.
Material was maximized in both width and thickness around both 25mm holes where
necessary. Large curves were used where possible to lower stress values.

Bearing load value unknown (200-250 lb range?), Legend values too low.

Initial Hook Design Calculations:

Max load calculation for the top hole stress concentration:
t= 5/16

d=0.75

w=1.625 max= 4350psi given

d/w = 0.75/1.625 = 0.462

Using Table A-22-4 to find Kt
Kt=~2.78
Fmax= (1.625 0.75)(0.3125)(4350) =1190lb
Max Load = 1190/2.78 Max Load= 428lb

Bending max load:

max= 4350psi
d=~1.0
c=~0.45
I=bh3/12
I=.3125*(0.91)3 = .02in4
Max load= max =Mc/I
M=max(I)/c
M=4350(.020)/.45
M=190lbin

M=F(d)
F=M/d
F=190lbin/1in
F=190lb

Mid section max load (Tensile)

Area ~.600 at max thickness, .19 wide single sheet thick
A1=0.6*0.3125=0.1875in2
A2=0.19*0.0625=0.01188in2
max1= 4350psi*0.1875in2=816lbs
max2= 4350psi*0.01188in2=52lbs
max= max1+ max2 = 868lbs
Large discrepancy between max bending load and max hole value indicates work needs
to be done on the hole end. High mid-section capacity means more weight reduction is
required.
Design Development Discussion:
Considering our initial design results we changed where we removed material. We
designed the beam portion of our hook into an I-beam profile to remove weight in areas
where there was low stress, as well as some material from the open end of the hook.
Inside face of the beam section was given a more elaborate curved profile to lower the
stress values seen in FEA. We then looked into a closable hook with equal loading on
both sides with a pinned end. After doing stress calculations on pinned holes we
realized that we could not rely on pins and holes with the given area on the open end of
our hook. We then used what we learned from the hole calculations to add a support
strap to our secondary hook. This hook was called hook 2+, to show an evolution of our
second iteration. The flanges of the I-beam was originally thicker than they needed to
be because we were concerned with the strength of abs glue. For the same reason our
end plates didnt maintain an I-beam profile, this was a design decision made during
fabrication. In the end we used an internal hollow profile to keep the weight of our hook
down. We lowered the amount of the material on the pinned end, most from the internal
plates, to get our final load capacity more in line with that of the other stress
concentrations in our hook, and the total estimated load capacity. Part of the plan was to

have the straps take on load after the main hook had already started to carry a
significant portion of the load due to the fact that the straps were a major stress concern
and werent able to support equal loading. This was achieved by slotting the holes in the
straps slightly.

Initial closeable hook, before Kt values had been calculated.

Final Design Calculations:

Max Load for The Strap pinned Hole
Hole diameter= 5mm= 0.1969in
Thickness= 5/16inch= 0.3125in
max= 4350psi
Stress=Kt(F/A)
4350=2.8(F/0.07519)
F=(4350x0.07519)/2.8
F= 116.8lb

Width= 7/16inch= 0.4375in

d/w= 0.1969/0.4375= 0.45

Kt=2.8

Max Load for Strap Hole Stress Concentration (as per given sheet width)
Hole diameter= 5mm= 0.2 in
Thickness= 2*1/16inch= 0.125in
max= 4350psi

Width= 7/16inch= 0.4375in

d/w= 0.2/0.4375= 0.45 Kt=2.8

Stress=Kt(F/A)
4350=2.8(F/0.0301)
F=(4350x0.0301)/2.8
F= 46.7lb (Total)
Pin Calculations
Pin dia=5mm=0.2in
2
Shear area= A= r

*2

max= 4350psi/2 (shear)

max= 2175(0.0628)
Max shear for 5mm pin=137lb
Max Load for The Top Hole Stress Concentration
(TWO OUTER PLATES)
Hole diameter= 0.75in
Thickness= 2*1/16inch= 0.125in

Width= 1.5in
d/w= 0.75/1.5= 0.5 Kt=2.6

Stress=Kt(F/A)
4350=2.6(F/0.09375)
F=(4350x0.09375)/2.6
F=156.8lb
(INNER PLATES)
Hole diameter=0.75in
Thickness=3*1/16in = 0.1875

Width=1.125
d/w=0.75/1.125 = 0.67 Kt=2.2

Stress=Kt(F/A)
4350=2.2(F/0.0301)
F=(4350x0.0703)/2.2
F= 139lb
Pinned hole total = 157+139 = 296lb. Chamfer added to outer layer inner plates, so
~300lbs min.

Bending stresses (as built)

Part
1

Ai
0.273

Yi
0.4375

AiYi
0.1194

Ii
0.01744

0.084

0.3625

0.0304
5

0.001929

di
0.0177
5
0.0572

Aidi2
0.000037
6
0.000099
6

Ii+Aidi2
0.017478
0.002029

IT=0.0155in4
C=0.4197in
max= 4350psi
d=0.7947in
c=0.4197in
I=0.0155in4
Max load= max =Mc/I
M=max(I)/c
M=4350(.0155)/.4197
M=160lbin

M=F(d)
F=M/d
F=160lbin/.7947in
Fmax=201in

Hook Specs:
Final Weight: 25.28g (26.xx g before breakage)
Max Load Closed: 1616N (from video), 1600N as recorded. (362/359lbs respectively)
Max Load Open: 1450N (from video)(300lbs)
Load/weight ratio: 6452
Glue-Hardware store ABS Cement

Hook pictures:

Performance Analysis and Future Development:

The hook failed at the end of our (handicapped) straps. This happened because the other two
straps broke off due to mishandling by Jeroen. On the outer strap the hole was reinforced with an
extra layer of abs to lower the Kt value to match loading capabilities of the pin. The second place
our hook broke was in the bending load portion of the hook. We assume it broke where it did
because the hollow portion of the hook extended well into the bending load portion and this
created a weak spot. It performed better than expected considering the broken straps, even if the
straps hadnt been broken off, our expectations still would have been greatly exceeded because
we expected the hook to fail way earlier. We were all surprised at the results because we didnt
think that it would perform well without all 4 straps. We would not break the straps off the part
because in the future as this greatly increased our stress risers on the holes in the strap. We would
also make the straps wider at the holes because thats what failed first. We also would have test
fitted our hook so when the test day arrived we would not do any last minute sanding and filing
to our hook. More material could have been removed from the beam side if we had tested a more
reliable way to join the hook together. Testing a proper strap slot clearance to ideally load the
main portion may result in a better value. Removing even more excess material from the closed
end due to the fact that it showed no signs of being stressed.