Simulation of AJWSP10033_FOLDED _ST_FR
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1 Phone: Simulation of AJWSP10033_FOLDED _ST_FR Date: 06 May 2017 Designer: Study name: AJWSP10033_FOLDED_STATIC Analysis type: Static Description The purpose of this analysis is to investigate the structural integrity of a Freestanding Internal Totem, which is intended to provide directional wayfinding and illumination to station concourse areas. There are two configurations for this product, one designed with box section galvanized steel, which is the subject of separate analyses, and the second with folded sheet metal galvanized steel, which is the subject of this static analysis. We not only provide comprehensive study properties, results and conclusions for this analysis, but also provide comparisons between the two static studies, together with those of frequency studies which are also performed for each design, so facilitating further conclusions to be drawn. Table of Contents Description... 1 Simulation Preparation Considerations... 2 Model Information... 3 Study Properties... 5 Study Results Table of Frequency Mode Comparisons Conclusion Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 1
2 Simulation Preparation Considerations For the purposes of this simulation, the following considerations are employed: All loadings are assumed to be static. Global bonding is applied. All unnecessary fasteners, washers, features, parts and subassemblies are excluded from this analysis. Fixed geometry is employed at the base of the design in order to simulate its fixity to the ground. A vertical load of 862.4N is applied to the uppermost surface of the design in order to simulate the gravitational force exerted due to the luminaire, which is excluded from this study. A vertical load of N is applied to the uppermost surface of a plate in order to simulate the gravitational force exerted due to components excluded from this study. Where the design is subject to barrier loadings, they should be designed to resist, without damage, the loads specified in BS These are all incorporated into this study and are: A horizontal uniform distributed line load of 1.5kN/m, applied at 1.1m above FFL. A uniformly distributed load of 1.5kN/m 2, applied to the infill, i.e. the full area between FFL and 1.1m above FFL. Where the signage can be reached by members of the public, minimum impact point loads of 1kN horizontally and 2kN vertically are applied. Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 2
3 Assumptions Model Information Solid Bodies Document Name and Reference Model name: AJWSP10033_FOLDED_ST_FR Current Configuration: Default Treated As Volumetric Properties Document Path/Date Modified Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 3
4 End Fill 2 End Fill 2 Boss-Extrude24 Solid Body Solid Body Solid Body Mass: kg Volume: m^3 Density:7870 kg/m^3 Weight: N Mass: kg Volume: m^3 Density:7870 kg/m^3 Weight: N Mass: kg Volume: m^3 Density:8027 kg/m^3 Weight: N C:\Business Paraphernalia\AJ Wells & Sons Ltd\AJWSP10033\Simulati ons 1\AJWSP SLDPRT Apr 12 10:58: C:\Business Paraphernalia\AJ Wells & Sons Ltd\AJWSP10033\Simulati ons 1\AJWSP SLDPRT Apr 12 10:58: C:\AJ Wells & Sons Ltd\AJWSP10033\Simulati ons 1\AJWSP10033_27_1.SLD PRT May 06 12:25: Boss-Extrude24 Solid Body Mass: kg Volume: m^3 Density:8027 kg/m^3 Weight: N C:\AJ Wells & Sons Ltd\AJWSP10033\Simulati ons 1\AJWSP10033_27_1.SLD PRT May 06 12:25: Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 4
5 Study Properties Study name Analysis type Mesh type Thermal Effect: Thermal option Zero strain temperature Include fluid pressure effects from SOLIDWORKS Flow Simulation Solver type Inplane Effect: Soft Spring: Inertial Relief: Incompatible bonding options Large displacement Compute free body forces Friction Use Adaptive Method: Result folder AJWSP10033_FOLDED_STATIC Static Mixed Mesh On Include temperature loads 298 Kelvin Off FFEPlus Off Off Off Automatic Off On Off Off SOLIDWORKS document (C:\Business Paraphernalia\AJ Wells & Sons Ltd\AJWSP10033\Simulations 2\Simulation 2 Runs) Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 5
6 Units Unit system: Length/Displacement Temperature Angular velocity Pressure/Stress SI (MKS) mm Kelvin Rad/sec N/ Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 6
7 Material Properties Model Reference Properties Components Name: Galvanized Steel Model type: Linear Elastic Isotropic Default failure Max von Mises Stress criterion: Yield strength: e+008 N/ Tensile strength: e+008 N/ Elastic modulus: 2e+011 N/ Poisson's ratio: 0.29 Mass density: 7870 kg/m^3 SolidBody 1(Fillet2)(AJWSP ), SolidBody 1(Speaker Bracket Holes)(AJWSP ), SolidBody 1(Speaker Bracket Holes)(AJWSP ), SolidBody 1(Cut- Extrude1)(AJWSP ), SolidBody 1(Holes)(AJWSP ), SolidBody 1(Holes)(AJWSP ), SolidBody 1(Cable Entry)(AJWSP ), SolidBody 1(Cable Entry)(AJWSP ), SolidBody 1(Chamfer1)(AJWSP ), SolidBody 1(Chamfer1)(AJWSP ), SolidBody 1(Fillet1)(AJWSP ), SolidBody 1(Split Line2)(AJWSP ), SolidBody 1(Split Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 7
8 Line2)(AJWSP ), SolidBody 1(Convert- Solid1)(AJWSP ), SolidBody 1(Split Line5)(AJWSP ), SolidBody 1(Cut- Extrude1)(AJWSP ), SolidBody 1(Fillet1)(AJWSP ), SolidBody 2(Fillet2)(AJWSP ), SolidBody 1(CSK for M6 Countersunk Flat Head1)(AJWSP ), SolidBody 1(Convert- Solid2)(AJWSP ), SolidBody 1(Split Line11)(AJWSP ), SolidBody 1(Convert- Solid1)(AJWSP ), SolidBody 1(Convert- Solid1)(AJWSP ), SolidBody 1(End Fill 2)(AJWSP ), SolidBody 1(End Fill 2)(AJWSP ), SolidBody Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 8
9 1(Holes)(AJWSP ) Curve Data:N/A Curve Data:N/A Curve Data:N/A Name: AISI Type 316L stainless steel Model type: Linear Elastic Isotropic Default failure Max von Mises Stress criterion: Yield strength: 1.7e+008 N/ Tensile strength: 4.85e+008 N/ Elastic modulus: 2e+011 N/ Poisson's ratio: Mass density: 8027 kg/m^3 Shear modulus: 8.2e+010 N/ Thermal expansion 1.65e-005 /Kelvin coefficient: Name: AISI Type 316L stainless steel Model type: Linear Elastic Isotropic Default failure Unknown criterion: Yield strength: 1.7e+008 N/ Tensile strength: 4.85e+008 N/ Elastic modulus: 2e+011 N/ Poisson's ratio: Mass density: 8027 kg/m^3 Shear modulus: 8.2e+010 N/ Thermal expansion 1.7e-005 /Kelvin coefficient: SolidBody 1(Holes)(AJWSP ), SolidBody 1(Boss- Extrude24)(AJWSP10033_27_ 1-1) SolidBody 1(Boss- Extrude24)(AJWSP10033_27_ 1-2) Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 9
10 Loads and Fixtures Fixture name Fixture Image Fixture Details Entities: Type: 1 face(s) Fixed Geometry Fixed-1 Resultant Forces Components X Y Z Resultant Reaction force(n) e Reaction Moment(N.m) Load name Load Image Load Details Force-2 Entities: 1 face(s) Type: Apply normal force Value: N Force-3 Entities: 1 face(s) Type: Apply normal force Value: 2000 N Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 10
11 Force-4 Entities: 1 face(s) Type: Apply normal force Value: 1000 N Force-5 Entities: 4 face(s) Type: Apply normal force Value: N Pressure-1 Force-6 Entities: 23 face(s) Reference: Edge< 1 > Type: Along Edge Value: 1500 Units: N/ Phase Angle: 0 Units: deg Entities: 1 face(s) Type: Apply normal force Value: N Force-7 Entities: 11 face(s) Type: Apply normal force Value: N Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 11
12 Connector Definitions Edge Weld Connector Model Reference Connector Details Edge-weld Size Graph Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 12
13 Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 13
14 Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 14
15 Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 15
16 Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 16
17 Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 17
18 Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 18
19 Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 19
20 Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 20
21 Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 21
22 Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 22
23 Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 23
24 Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 24
25 Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 25
26 Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 26
27 Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 27
28 Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 28
29 Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 29
30 Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 30
31 Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 31
32 Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 32
33 Edge Weld Connector Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Edge Weld Connector Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 33
34 Weld size (mm.) Weld throat size (mm.) Joint normal Shear-Weld axis Bending moment (N.m) Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 34
35 Contact Information Contact Contact Image Contact Properties Contact Set-655 Type: No Penetration contact pair Entites: 2 face(s) Advanced: Node to surface Contact/Friction force Components X Y Z Resultant Contact Force(N) E E-017 Contact Set-656 Type: No Penetration contact pair Entites: 2 face(s) Advanced: Node to surface Contact/Friction force Components X Y Z Resultant Contact Force(N) Contact Set-657 Type: No Penetration contact pair Entites: 2 face(s) Advanced: Node to surface Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 35
36 Contact/Friction force Components X Y Z Resultant Contact Force(N) Contact Set-658 Type: No Penetration contact pair Entites: 2 face(s) Advanced: Node to surface Contact/Friction force Components X Y Z Resultant Contact Force(N) Global Contact Type: Bonded Components: 1 component(s) Options: Compatible mesh Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 36
37 Mesh information Mesh type Mesher Used: Jacobian points Jacobian check for shell Maximum element size Minimum element size Mesh Quality Plot Remesh failed parts with incompatible mesh Mixed Mesh Curvature-based mesh 4 Points On mm mm High Off Mesh information - Details Total Nodes Total Elements Time to complete mesh(hh;mm;ss): 00:01:06 Computer name: Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 37
38 Sensor Details No Data Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 38
39 Resultant Forces Reaction forces Selection set Units Sum X Sum Y Sum Z Resultant Entire Model N e Reaction Moments Selection set Units Sum X Sum Y Sum Z Resultant Entire Model N.m Beams No Data Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 39
40 Study Results Name Type Min Max Stress1 VON: von Mises Stress 0.000e+000N/ Node: e+009N/ Node: AJWSP10033_FOLDED_ST_FR-AJWSP10033_FOLDED_STATIC-Stress-Stress1 Name Type Min Max Displacement1 URES: Resultant Displacement 0.000e+000mm Node: e+001mm Node: Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 40
41 AJWSP10033_FOLDED_ST_FR-AJWSP10033_FOLDED_STATIC-Displacement-Displacement1 Name Type Min Max Strain1 ESTRN: Equivalent Strain 0.000e e-003 Element: Element: Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 41
42 AJWSP10033_FOLDED_ST_FR-AJWSP10033_FOLDED_STATIC-Strain-Strain1 Name Type Min Max Displacement2 UX: X Displacement e-001mm 2.102e-001mm Node: Node: 9826 Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 42
43 AJWSP10033_FOLDED_ST_FR-AJWSP10033_FOLDED_STATIC-Displacement-Displacement2 Name Type Min Max Displacement3 UY: Y Displacement e+001mm 7.324e+000mm Node: Node: Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 43
44 AJWSP10033_FOLDED_ST_FR-AJWSP10033_FOLDED_STATIC-Displacement-Displacement3 Name Type Min Max Displacement4 UZ: Z Displacement e+000mm 1.688e+000mm Node: Node: Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 44
45 Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 45
46 Table of Frequency Mode Comparisons From frequency studies AJWSP10033_BOX_FREQUENCY, AJWSP10033_BOX_FREQUENCY-2, AJWSP10033_FOLDED_FREQUENCY and AJWSP10033_FOLDED_FREQUENCY-2, we observe the following frequency mode comparisons: Box Section Without Damage Box Section With Damage Folded Sheet Metal Without Damage Folded Sheet Metal With Damage Mode Shape1 /(Hz) Mode Shape 2 /(Hz) Mode Shape3 /(Hz) Mode Shape 4 /(Hz) Mode Shape 5 /(Hz) Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 46
47 Conclusion We make the following observations and conclusions: The maximum von Mises stress occurs at the 2kN point load. However, this effectively represents a singularity and this therefore physically unrealistic. We can therefore ignore this stress. The maximum stress induced due to crowd loading (1.5kN uniformly distributed horizontal load and 1.5kNm -1 horizontal line load) is 3.739x10 7 Nm -2, significantly lower than the yield strength of galvanized steel, which is 2.04x10 8 Nm -2. This occurs on the lower, central sheet metal plate (part no. AJWSP ). We conclude therefore that these loadings should not present any issues. Please refer to the image below: From the plot shown on page 44, the maximum vertical deflection occurs at the extreme end of the sign where the point loads are applied, and has magnitude 13.99mm. This represents a 32.7% increase in deflection as compared to the box section study, AJWSP10033_BOX STATIC. The highest physically realistic stress occurs at the interface between the sign which has the point loads applied and subassembly AJWSP , which has magnitude 1.592x10 8 Nm -2, quite close to the yield strength of galvanized steel. Please refer to the image below for clarification: Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 47
48 Note the green areas indicating areas of high stress. The simulation suggests therefore that this is the area that will fail first. Also, since this plate is in turn connected to the sign under load, this may well explain the higher vertical deflection, as compared to the box design. It is worth considering a thicker gauge of sheet metal for this part. From pages 12-34, with the exception of Edge Weld 24 (predicted weld size 5.98mm), all reported suggestions for the weld sizes remain either below or well below 4mm. Therefore, this aspect of the design should not present any problems. Please refer to the image below for the position of Edge Weld 24: Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 48
49 If we consider a typical cross-section for the box section (please refer to the image below), we obtain a moment of inertia of the area, at the centroid, about a horizontal axis rotating into the page, of 1.98x10 7 mm 4 : Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 49
50 Similarly, for the folded sheet metal design (please refer to the image below), we obtain a value of 1.47x10 7 mm 4 : Therefore, we see that the folded sheet metal design is typically weaker in lateral bending than the box section design. This could also go some way towards explaining the greater maximum vertical deflection of the folded sheet metal design. We see from the Table of Frequency Mode Comparisons, given on page 46, that all of the fundamental resonant frequencies are around 8Hz, so giving a factor of safety of approximately 2 for the pass criterion of 4Hz minimum. Should a higher factor of safety be required, we offer the following additional design modification suggestions: (i) (ii) Consider varying the gauges of sheet metal for the design of subassembly AJWSP Consider varying the height of parts AJWSP and AJWSP Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 50
51 (iii) (iv) Consider varying the wall thickness for the 60x40 box section. Consider varying the dimensions of the folded geometry of parts AJWSP and AJWSP Please refer to the image below for an example area for clarification: Ideally, a design study would be appropriate, incorporating different combinations of the suggestions above, so converging upon an optimal design, or at least as close as we can get to one. Preliminary design studies have already been performed concerning and the results indicate that the suggestions given above can be very effective in pushing the fundamental resonant frequency up even further. Analyzed with SOLIDWORKS Simulation Simulation of AJWSP10033_FOLDED_ST_FR 51
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