The crane wheel depicted in the following example was to be re-rated to take substantially higher loadings. The client engaged us to construct an FEA Model to check that stress concentrations and stress levels within the wheel would be satisfactory. Stresses in the area of contact with the rail rim were found to be in excess of allowable levels, thus rendering the wheel to be unsatisfactory for the full range of proposed crane movements and loadings. As a result, the crane was modified with the addition of an extra wheel and modified cross beam so as to reduce wheel loadings to acceptable levels.

The FEA method quickly and inexpensively examined the stress distribution and concentrations within the wheel, an outcome that could only be roughly approximated by traditional design methods.

Temco Bell Bay were experiencing repeated failure of a chain link on a casting machine. Finite Elements were engaged to perform an FEA stress analysis of the link to confirm the existence of a stress concentration as the initial stage.

Progressive refinement of the FEA mesh in the region of interest, made it possible to achieve a high level of detail on the critical focus of the model.

The second stage involved modelling a number of geometrical improvements in order to determine which modifications would provide benefits and which would not.

Due to the complex geometry of a high temperature atomising head that sprays molten aluminium, an FEA model was essential to show that the combination of thermal and pressure induced stresses would stay within recognised design guidelines.

The model was constructed from brick elements and included insulation, transient heat transfer and pressure stresses. The model clearly showed that the design of the atomising head would require modification in a number of areas in order to meet the design criteria. The FEA model formed the basis for the subsequent iterative refinement of the design which Finite Elements undertook over a number of weeks.

For more details on this project, click on the image above....