ABSTRACT The study focuses on evaluating the nonlinear structural strength of steel chains in lifting operations, particularly in contact with knuckle-shaped plates, under various loading conditions. Using finite element analysis (FEA), the research examines how different contact angles (0°, 45°, 90°) and materials (SS400, HT32, HT36, ASTM A356) influence the chain’s performance under tensile loading. The analysis categorises four main loading conditions, referred to as 0 degree through 45 degrees to symmetric direction, each representing different orientations of the chain relative to the lifted object. Among these, lifting at 90 degrees consistently showed the lowest ultimate strength across all materials and chain sizes. The primary cause of this weakness was identified as significant stress concentration at the central link, where the loading angle of 90 degrees led to early yielding. This critical loading condition not only reduced the chain’s load-bearing capacity but also increased the risk of premature failure due to localised stress buildup. The study further highlights that as the yield strength of the material increases, the difference in load capacity between non-symmetric 45 and 90 degrees becomes more pronounced, with 90 degrees lifting exhibiting lower strength across the board. For instance, ASTM A356, although generally stronger than SS400, still demonstrated a notable reduction in load capacity under 90 degrees lifting. Mesh convergence tests were performed to ensure the accuracy of the FEA results, confirming that 12 mesh elements were sufficient to accurately model stress distributions. The results also indicated that increasing the chain diameter could improve load-bearing capacity under most loading conditions, but even larger chains were still vulnerable under 90 degrees lifting. In conclusion, 90 degrees lifting presents a critical design challenge due to its inherent weakness, and mitigating stress concentration at the central link is key to improving chain durability and safety. This study’s findings offer valuable insights for engineers, particularly in the shipbuilding and offshore industries, on how to optimise chain design and improve safety in hoisting operations.
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