Experimental strain evaluation and generative design optimization of a crane hook using finite element analysis

Abstract

Crane hooks are safety-critical mechanical components used for lifting heavy loads, and their structural integrity directly affects operational reliability. The conventional crane hook designs based on analytical approaches may lead to conservative geometries with excessive material usage. This study investigated the generative design optimization of a crane hook modeled in accordance with the DIN 15401 standard. Experimental strain measurements were conducted at the critical cross-section of the hook under axial loading conditions. The measured strain responses were compared with finite element analysis results and used to improve the definition of the numerical material parameters. After establishing the finite element model, design constraints, preserved regions, obstacle regions, and boundary conditions were defined for the generative design process. The final optimized crane hook achieved an approximate weight reduction of 39.4% compared with the classical design while maintaining stresses below the material yield strength. The results show that experimental strain evaluation combined with finite element analysis can provide a useful basis for assessing and guiding generative design optimization of crane hook geometries.