Topic:
Design Considerations
Type of loads
1. Static load
2. Dynamic load
1. Static load- Load does not change in magnitude and direction and normally increases
gradually to a steady value. In static analysis, time is constant.
2. Eg: storage tank containing milk: constant weight (liquid load), Weight of food
processing machines.
Types of Static stress/load
Tensile Stress – due to pulling force
Compressive Stress – due to pushing force
b) Dynamic load- Load may change in magnitude, direction & varies with time.
for example, traffic of varying weight passing a bridge, Rotating blades of mixer or
grinder, Bottle filling machine
Types of dynamic loads
Combined stress & design stress
Combined stress: different types of stresses acting on a material simultaneously.
Basic three loading and their corresponding stresses;
1. Axial loading: 𝝈 = P/A.
2. Torsional loading: t = T .r/J.
3. Bending loading: 𝝈f = My/I
The possible combination of these stresses are: axila + blending ; axial + torsional
Design stress
The design stress is the maximum safe stress that a material can
withstand before failure under actual working conditions. It is also called
ultimate stress.
It ensures the structure or machine part remains safe and durable.
Theories of failure
Provided separate pdf
Fabrication method
Fabrication is the process of manufacturing metal structures or components by cutting, shaping, and assembling
different parts—usually through welding, riveting, or bolting.
Types of Fabrication Processes
Cutting
Cutting involves splitting or cutting the metal material down into smaller sections. When creating large scale
fabrication cutting may be used to create the desired sections. Large sheets of metal will be cut down into either
halves or thirds before being shaped however, pre shaped metals may also use the cutting process. This can be done
through advancements in technology and cutting tools including water jet cutting, laser cutting, CNC (computer
numerical computer) cutting machines.
Forming
Forming is a common metal fabrication process to create a shape or a fold in the metal material. The process
involves manipulating the piece of metal forming a bend that is usually done at a 90-degree angle. Forming requires
high tech equipment to form shapes in the metal such as CNC press brakes or rolling machines.
Punching
Punching is the process of creating holes in metal workpieces by punching them in using specific machinery. Using metal
sheets, the punching device will cut and punch desired shapes or holes on the flat surface of the metal. This can be done
using CNC Turret Punch Machines for large scale fabrication. Smaller hand powered punching devices may be used for
small scale fabrication.
Shearing
Shearing is a similar process to cutting. It involves removing unwanted material or excess metal material by trimming it in one
long cut. One long straight cut is achieved by having two blades: One above the piece of metal and one below the metal. It is the
perfect tool for cutting smaller lengths or different shape materials as the as the blades are able to be mounted at angles.
Stamping
Another fabrication process that is common and similar to punching. Unlike punching, Stamping will create an indentation as
opposed to punching a hole in the metal. Stamping is done to create letters, shapes or images into a sheet of metal. Stamping
machines are often used for coining and four slide forming.
Welding
Welding is probably the most popular fabrication procedure used. Welding involves joining multiple pieces metal together
through heat and pressure. The welding process can be used for different types of metal to create any shapes and sizes.
The most popular types of welding are MIG and TIG welding, stick or arc welding and spot and stud welding.
MIG (Metal Inert Gas) Welding and TIG (Tungsten Inert Gas) Welding are two of the most common welding procedures we
use at FEM for many of our fabrication projects for all industry needs including the construction industry.
Machining
Machining is the process of removing unwanted material from the metal by shaping it. This is commonly done using CNC
Machining to ensure the measurements are precise.