Comparative Stress Analysis and Parametric Optimization of Crane Hooks Using Finite Element Analysis
Received: 19 November 2025 | Revised: 18 December 2025 and 9 January 2026 | Accepted: 27 January 2026 | Online: 4 April 2026
Corresponding author: Norie A. Akeel
Abstract
Crane hook failure is associated with high stress concentrations at the inner curvature. Finite Element Analysis (FEA) is widely used to evaluate crane hook performance; however, simplified analytical methods can deviate significantly from numerical results, particularly for highly curved geometries. To address this issue, the current study presents a structured methodology comprising three main components: (1) a mesh convergence study to ensure the accuracy and reliability of the FEA model, (2) a systematic comparison between classical analytical calculations and three-Dimensional (3D) finite element simulations, and (3) a Parametric Sensitivity Analysis (PSA) to identify the geometric parameters that most influence structural integrity. A 3D crane hook model was developed in SolidWorks and analyzed under a vertical load of 70 kN, using plain carbon steel with a yield strength of 220.5 MPa. The mesh convergence study confirmed solution stability with 19,703 nodes and 12,656 elements. The FEA results indicated a maximum von Mises stress of 490.2 MPa at the inner curvature, compared with an analytical prediction of 484.6 MPa, corresponding to a minimum Factor of Safety (FoS) of 1.06. Parametric variation of key geometric features showed that the inner radius has the greatest effect on stress concentration; a 15% increase in the inner radius resulted in approximately 40% improvement in FoS. The results show that increasing the inner radius is the most effective means of enhancing structural safety, followed by thickness modification and material upgrading. This study provides validated guidelines for reliable FEA of crane hooks and establishes a priority-based design optimization framework. This approach moves beyond conventional isolated analysis and offers practical, hierarchy-driven recommendations for safer crane hook design.
Keywords:
crane hook, stress concentration, mesh sensitivity, convergence analysis, structural failureDownloads
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Copyright (c) 2026 Norie A. Akeel, Vinod Kumar, Abdoulhdi B. Omran, Issa Alkharusi, Nasser Alanbouri
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