CHAPTER 6

CALCULATION OF REQUIRED DESIGN

6.1

Calculation from experimental results

In this section, we will calculate the hoop stress not only for the pulling load but also
for the braking load for the 1st layer of rope on the drum body due to the compressive
stress. Also, the pressure occurred when a loaded rope is wound onto a winch drum,
wrap by wrap; each successive wraps compress the drum in its area of contact (Refer
to section 3.4). Afterward, we will compare the hoop stress between design codes and
calculated results for both of the loading conditions.

6.2

Calculation for required drum thickness

According to the experimental results, the loaded rope tension throughout the winch
operation is decreasing from far end to near end of the drum whether there is a pulling
load or braking load applied on the drum. As a result, it is shown that the assumption
of uniform tension along the loaded rope is not supported by our experimental results.
Thus, the calculation of hoop stress in this section will be used with decreasing
pressure that acting on the drum by the rope tension due to the pulling or braking load
(Figure 6.1).

As discussed in section 3.4.3 and 3.5, the Hampes solution method gives more
realistic data to get an improve design. Moreover, one of the advantages of this
solution has provided a calculation on each and every wraps continuously onto the

47

winch drum; which we can observe the deflection as well as hoop stress occurring in
each positions under the respective warps on the winch drum in pulling or braking
load conditions.

As mentioned in the Chapter 3, our analysis is based on one particular design of the
winch, which is currently being used, with the following design parameters:

Drum diameter

1000 mm

Drum Length

1775 mm

Drum thickness

70 mm

Steel wire rope size (diameter)

65 mm

Applied tension load (pulling)

200 tons

1.96 MN

(1ton = 1000kg = 9810N)

Applied tension load (braking)

300 tons

2.94 MN

(1ton = 1000kg = 9810N)

Yield Stress for steel (ST 52.3)

520 MPa

The general formula based on the Hampes solution [9], the hoop stress, h is:

h =

N E
E
= w p ( ) + S1 F7 ( ) + S 2 F15 ( ) + S 3 F16 ( ) + S 4 F8 ( ) ] = [w]
t
R
R

(6.1)

The derivation of the above equation and the various terms are discussed in Appendix
A.

48

Deflection, w, is given by,

w = w p ( ) + S1 F7 ( ) + S 2 F15 ( ) + S 3 F16 ( ) + S 4 F8 ( )

where, the ordinates of deflection line, wp is: w p ( ) =

The non dimensional coordinate of =

(6.2)

P R2
Et

(1 )

(6.3)

x
,
L

(6.4)

where (0 1): can be seen in Figure 6.1.

According to the above formulae, account is taken for the decreasing pressure applied
to the drum as illustrated in Figure 6.1.

=0.25

Pressure (P)

=0.75
=1

=0

y=0.5

Drum

Near end

Drum thickness = t

R
D
Far end

Rope
Wraps
Load

Fig 6.1 Illustration of cylindrical shells affected by external decreasing pressure

49

6.3

Calculated results for pulling load process

For a pulling load of 200 tons and drum thickness of 70 mm, the hoop stress exerts
onto the drum due to the load at each respective positions with the number of wraps
on the drum is as shown in Figure 6.2. According to our calculated results, the highest
hoop stress occurs when the applied load is at =0.8 from the near end of the drum
due to the pulling load. The details calculation of maximum hoop stress is as shown in
Appendix A. However, the highest hoop stress caused by uniform pressure has a
magnitude of 429 MPa according to Table 3.2 method III as drawn in dashed line. So
that, the percentage difference of highest hoop stress between the design codes and
our results is 19%.

Therefore, it can be accomplished that the highest hoop stress, what we called a worse
case scenario, occurs at =0.8 from the near end of the drum and has a magnitude of
348.4 MPa. As a result, we can reduce certain amount of required drum thickness
compared to the design codes.
Hoop stress on the drum after pulling load applied at respective position
0
Const

-90

S tres s in M P a

=0

-180

=0.25
=0.5

-270

=0.8

-360

=1

-450
1

13

Wraps

17

22

27

Fig 6.2 Hoop stress at each respective positions on the drum applied by pulling load

50

6.4

Calculated results for braking load process

For a braking load of 300 tons and drum thickness of 70 mm, the hoop stress exerts
onto the drum due to the load at each respective positions with the number of wraps
on the drum is as shown in Figure 6.3. According to our calculated results, the highest
hoop stress occurs again at =0.8 from the near end of the drum due to the braking
load. The details calculation of maximum hoop stress is as shown in Appendix A.
However, the highest hoop stress caused by uniform pressure has a magnitude of 643
MPa according to Table 3.2, method III as drawn in dashed line. This design codes
maximum hoop stress is higher than the permissible stress level. However, our
calculated maximum hoop stress is within the permissible level. Also, the percentage
difference of highest hoop stress between the design codes and our results is 42%.

Therefore, it can be accomplished that the highest hoop stress, what we called a worse
case scenario, caused by decreasing pressure occurs again at =0.8 from the near end
of the drum, whether the braking load is at that point or not and has a magnitude of
370.7 MPa. As a result, we can also reduce the certain amount of required drum
thickness compared to the design codes.

51

Hoop Stress on the drumafter braking the load at respective position

0
-100

Const

Stress (MPa)

-200

=0

-300

=0.25

-400

=0.5

-500

=0.8

-600

=1

-700
1

13

Wraps

17

22

27

Fig 6.3 Hoop stress at each respective positions on the drum applied by
braking load

52

6.5

Relationship between pulling and braking load

The main difference between these two process is the winding the rope on the drum.
In the coiling (pulling) load process, the loaded rope is wound onto a winch drum in
wrap by wrap starting from the near end to the desire position. Also, each successive
wraps compress by radial pressure inwards on to the winch drum. As for the braking
load, the unloaded rope was wound on the drum from the near end to the desired
position before the load was being applied; unlike the process of coiling the loaded
rope has been done on the drum. The comparison of loading type between these two
applications can be clearly seen on the Figure 6.4 as below.

Braking load application

Pulling load application

Fig 6.4 Comparison of braking and pulling load in actual winch operation

Even though these two processes are different, the maximum hoop stress occurs in the
same position, which is =0.8 from the near end of the winch drum. In addition, the
magnitude of maximum hoop stress in pulling and braking load application at =0.8 is
348.4 MPa and 370.7 MPa, respectively.

53

In addition, Table 6.1 shows the comparison of maximum hoop stress at each
respective position between them. These calculated hoop stress will use to compute
required design.

Table 6.1 Maximum hoop stress at respective position for both applications

Maximum hoop stress (MPa)

Applied load position
Pulling Load 200 tons

Braking load 300 tons

=0

=0.25

110.4

141.8

=0.5

220

242

=0.8

348.4

370.7

=1

335.7

345.6

As can be seen in the above Table 6.1, although the load applications and magnitude
of load for each operations between the pulling load and braking load is different, the
maximum hoop stress occurs at the same position of around third quarter (=0.8) from
the near end of the drum. In addition, our calculated maximum hoop stress between
pulling load and barking are comparable as the different in percentage is only a 5%;
the weight of braking load should be 1.5 times or less heavily than the weight of
pulling loads.

54

6.6

Design code verses calculated results

According to the literature survey and our calculations, the DNV design guide gives
more realistic, more suitable and more easier to compute the required design of winch
drum, even though their formula are quite similar with SAA design guide. The only
difference between these two design guides is the assumed maximum permissible
stress. Therefore, the DNV design guide has been selected to compare with our
calculated results and compute the maximum hoop stress condition. The detailed
calculation of maximum hoop stress with actual operation data of DNV design code
can be seen in Chapter 3, Section 3.1. Table 6.2 shows that the comparison between
the DNV design guide and our calculated result output data.

Table 6.2 tabulates the maximum hoop stresses under the following conditions:

(a)

Uniform tension of the loaded rope in Design codes and Hampes Solution.

(b)

Decreasing tension of the loaded rope in Hampes Solution.

The percentage difference between the design codes and our results is 19% for the
pulling load condition and 42% for the braking load condition, respectively. These
percentage difference will be used to determine the required thickness of the improve
design.

55

DNV Code

520
442

430

646

Particular

Yield Stress in Steel ST 52.3,

MPa

Permissible Stress in MPa

Due to Pulling Load (200 tons)

with thickness 70 mm
(h < pe)

Due to Braking Load (300 tons)

with thickness 70 mm
(h > pe)
643

429

442

370.7

348.4

442

520

pressure

pressure
520

Decreasing

pressure

Uniform

42

19

pressure

Decreasing

DNV (%)

Hampes Solution Method

Uniform

Percentage variation with

Calculated result data with

Table 6.2 Comparison between DNV design code and calculated result data of Hoop Stress

56

6.7

Reinforced thickness for winch design

According to our calculated results, we found out that the other factor that can get a
revamping profitable design is to reinforce the thickness only in the certain area of the
winch drum, which will resist the higher compressive stress caused by the pulling or
braking load in the winch operations. As refer to the Figure 6.1 and 6.2, it can be
clearly seen that the maximum hoop stress occurred at around third quarter (=0.8)
from the near end of the drum with the drum thickness of 70 mm due to the pulling
load. Moreover, the maximum hoop stress also occurred at the same position in the
braking load process (Please see details in the section 6.4).

Even though the maximum hoop stress occurred at the same position between pulling
and braking load condition, the improve design in reinforced thickness of winch drum
will emphasize only on the pulling load condition as it gives more relevant data to see
the clearer visualization of the continuous coiling. However, the suggested improve
design guide will not only compute for pulling load, but also figure out for the braking
load as well. For convenience calculations, we separated three sections as shown in
Fig 6.6 which can apply the same formulae with this Hampe theory in separated
sections for the reinforced application thickness of the drum.

As can be seen in the Figure 6.5, the graph was plotted for the 200 tons pulling
loading condition throughout the winch drum with the required thickness of 60 mm.
The details specification is as follows:

(I)

Drum diameter

1000 mm

57

(II)

Drum Length

1775 mm

(III)

Drum thickness

60 mm

(IV)

Diameter of Steel wire rope size

65 mm

(V)

Applied tension load (pulling)

200 tons

(VI)

Yield Stress for steel (ST 52.3)

520 MPa

(VII) D/d ratio

15.4

(VIII) Maximum hoop stress

Please see Table 6.3 row (1)

= 1.96 x 106 N

Hoop stress on the 60 mm drum after pulling load applied at respective position
0
Const

-90

S tress in M P a

=0

-180

=0.25
=0.5

-270

=0.8

-360

=1

-450
1

13

Wraps

17

22

27

Fig 6.5 Hoop stress at each respective positions on the drum applied by decreasing
pressure in uniform thickness of 60 mm

Table 6.3 Required thickness of the winch drum correlated with maximum load

Thickness

Maximum weight of

Hoop Stress in MPa

loading in Tons

and position

of the drum

stress MPa
Pulling

60

Permissible

200

Braking

Pulling

Braking

407

437

300

442
nd

At =0.8 (22 wrap)

400
2

52

200

435
442

300
th

At =0.66 (18 wrap)

58

As can be seen in the Figure 6.5 and Table 6.3, the maximum hoop stress occurs at
=0.8 which is around third quarter of the 60 mm drum and has a magnitude of 407
MPa and 437 MPa for puling and braking load, respectively. However, the winch
drum had a capacity of 27 wraps of wire rope onto the full length of the drum.

According to the Figure 6.5 of pulling load application, the position of highest hoop
stresses occurred at =0.8 which is around third quarter of the drum, which means it
occur between the (=0.7) 19th to (=0.88) 24th wraps on the drum. So that, the total of
6 wraps (from 0.7 to 0.88 ) which have to withstand the highest hoop stress between
382 to 407 MPa according to our calculated results. From this result, we could say
that a quarter of total wraps on the drum has compressed the maximum hoop stresses
on the drum. The rest of the wraps, other than between these wraps, withstand the
hoop stresses are 366 MPa or less.

As a result, we can reduce the thickness the drum which is from near end (=0) to 18th
wraps (=0.66) and 25th wraps (=0.9) to far end (=0). (The details illustration can be
observed in Figure 6.6 and 6.7 as below). As can be seen in Table 6.4 row (2), the
hoop stress occurred at the 18th wraps (=0.66) and had a magnitude of 400 and 435
MPa in pulling and braking load, respectively for a 52 mm thickness of winch drum.

59

18th wrap (=0.66)

Pressure (P)

25th wrap (=0.9)

w

y
x

Drum

Section 1
L

Near end

Section 3

Far end

t2=60mm thick
t1=52 mm thick
Load
Fig 6.6 Illustration of cylindrical shells affected by external decreasing pressure in
reinforced thickness of drum

Hoop stress on the variable thickness drum after pulling load applied at respective position
0
=0

S tress in M P a

-90

=0.25

-180
=0.5

-270

=0.8
=1

-360
-450
1

13

Wraps

17

22

27

Fig 6.7 Hoop stress at respective wraps on the drum applied by decreasing pressure in
reinforced thickness of drum

The above Figures 6.6 and 6.7 shows that how the reinforced thickness of the winch
drums should be fabricated and how the hoop stress exerted onto the drum in each and
every position along the winch drum.

60

The detailed specification for modified winch drum in reinforced thickness is as

follows:

(I)

Drum diameter

1000 mm

(II)

Drum Length

1775 mm

(III)

Drum thickness, t1

52 mm

(The thickness of 52 mm is from near end (=0) to 18th wraps (=0.66, 1170 mm) and
25th wraps (=0.9, 1560 mm) to far end (=0))
(IV)

Drum thickness, t2

60 mm from 1170 (=0.66) to

1560 mm (=0.9)

(V)

Diameter of Steel wire rope size

65 mm

(VI)

Applied tension load (pulling)

200 tons

= 1.96 x 106 N

(VII) Applied tension load (braking)

300 tons

= 2.94 x 106 N

(VIII) Yield Stress for steel (ST 52.3)

520 N/ mm2 = 520 MPa

(IX)

D/d ratio

15.4

(X)

Maximum hoop stress in 60mm

407 MPa in pulling load

(XI)

Maximum hoop stress in 52mm

400 MPa in pulling load

(XII) Permissible stress of material

442 MPa

(XIII) Maximum hoop stress in 60mm

437 MPa in braking load

(XIV) Maximum hoop stress in 52mm

435 MPa in braking load

61

As above calculated thickness and their position, we can predict that the general form
of reinforced thickness into the certain area of the drum for fabrication is,

Length of the drum

Smaller thickness of the drum t1 is from 0 to 0.66 L and 0.9 L to L.

Larger thickness of the drum t2 is from 0.66 L to 0.9 L.

6.10

Recommended required design thickness

According to our calculated result, the following table 6.4 and 6.5 tabulate the
recommended thicknesses correlated with highest loadings for uniform thickness and
reinforced thickness, respectively.

62

60

3.

65

60

2.

3.

52

55

60

t1

200

200
300

300

300

407

376

349

Braking Pulling
load
load

437

403

375

442

442

442

Permissible
Braking stress MPa
Load

Maximum hoop
Stress in MPa

520

520

520

Material
Yield
stress
MPa

15.3

15.3

15.3

D/d
Ratio

200

200

200

Pulling

300

300

300

Braking

Maximum weight of
loading in Tons

407

376

349

Pulling

437

403

375

Braking

Maximum hoop
Stress MPa in t2

401

379

347

Pulling

435

412

377

Braking

Highest hoop
Stress MPa in t1

442

442

442

Permissible
stress MPa

520

520

520

Material
Yield stress
MPa

15.3

15.3

15.3

D/d
Ratio

65

65

65

Rope
Diameter

As mentioned details in Section 6.7 reinforced thickness calculation, t2 is from 0.66 L to 0.9 L and the rest is t1 for fabrication.

70

t2

Recommended
Thickness of
the drum (mm)

1.

Sr.

65

2.

200

Pulling
load

Maximum weight
of loading in Tons

Table 6.5 Recommended reinforced thickness of the winch drum correlated with maximum load

70

1.

Sr.

Recommended
Thickness of the
drum (mm)

Table 6.4 Recommended uniform thickness of the winch drum correlated with maximum load

65

65

65

Rope
Diameter

63