Static stress Simulation results

[josh.linares-stanley]

Hi,

Having some wild results from the static-stress simulation in fusion and wondered wheather anyone could make some recommendations.

As seen in the image, my structure is fixed to the lifting eye and a force applied down where necessary (1113kg*9.81)N to both the base and mid beams. All metal-to-metal (Steel) contact in real life has been fully seam-welded which I am finding difficult to replicate in fusion properly.

I should stress that a real life test has already been carried out for this scenario in which it passed with no casue for concern. Results given by fusion are often lower than a safety factor of 0.2.

Cheers,

Josh

[TheCADWhisperer]

Can you File>Export and then Attach your *.f3d file here?

Which part(s) do you need to test?  Do you need the entire assembly in order to test the high stress part(s)?

Do you have a stress riser that can be ignored?

You image shows the entire assembly rather than a close-up of the min stress area of concern?

What is your max displacement value?

Shouldn't this thread be over in the Design, Validate side of the forum rather than the "bugs/issues" side?

[josh.linares-stanley]

Hi,
Thanks for the reply

Where I have applied loads, I need to know the entire structure can withstand stress when being lifted from the eye. Loads are split into two with (1113kg*9.81) on the base plate (fork-lift frame), and (1113kg*9.81) supported by those beams, Image I have attached may provide a better representation. Displacement ranges between 1-3mm in the bottom corner of the assembly.

Kind regards,
Josh

[TheCADWhisperer]

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@josh.linares-stanleywrote:

1.  I need to know the entire structure can withstand stress
2.  Image I have attached may provide a better representation.
3.  Displacement ranges between 1-3mm in the bottom corner of the assembly.

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1. It appears that you have already verified that the high stress is in a limited area of the assembly.

I think I would simplify to isolate those components.

2. No additional image attached?

3. What is the max displacement in the area of the high stress?  (if all else is removed and replaced with appropriate load values)

[josh.linares-stanley]

Hi,

Yes it's mainly in the corners where you would expect the model to experiance the highest stress. I guess my real question is whether theres a way to effectively add material to those areas to act as welds, which are present in the real model. So far, my efforts to simply add material or add strength in other ways have had little-no effect on my results.

It's difficult to interpret any of the results as reliable as they seem to differ from the real thing so much. Wondered whether I may have been misinterpreting information and if there where any additional options/check i should have carried out.

(PS. yep, was meant for design,validate and document, my bad)

Cheers,

Josh

[TheCADWhisperer]

It appears that you attached the same image that you attached previously?

Adding material does not necessarily reduce stress (increase safety factor).

In fact, it might do just the opposite.

[TheCADWhisperer]

Bump.

Just moving this to the top so that I don’t forget to take a look at the file. 

[TheCADWhisperer · Accepted solution]

I would significantly simplify your assembly for analysis.

The only components needed are those in high stress.

I believe that you have a singularity that can be ignored - but I did not bother to investigate further as I would never set up an analysis without idealizing for the components of interest.