MAE 4363
Advanced Methods in Design
Project 2 Spring 2013
Dr.J.K.Good
 The mission is to build a frame from a blank of
6061-T6511 aluminum, 3/8” thick, as shown
below. The design constraints are:
 The loading
and restraint
locations
shown
 A failure
load as
close to
8000 lbs as
possible
 Minimal
weight
8,000 lbs
0.75”
All pins are 3/8” diameter
18”
6”
Your Frame Structure
5”
5”
5”
0.625”
Rigid Support
8,000 lbs
 Why is this a challenge for our students? I am
requiring them to design a redundant structure in the
inelastic range of a material. We train them through
the 3XXX level to design in the elastic range of
materials.
 They learn to:
 Use finite element analysis to determine internal
loads in frames
 Conduct plastic bending analyses
 Predict long and short column buckling using fea
 Predict bearing failures
 Predict failure to combined mechanisms in the
inelastic range of a material
 Is this realistic? Engineers who design to failure in the
aircraft and automobile industries do this daily.
 Each student produced their own preliminary design.
After cross checking calculations inside teams they
design, build and test the lightest design.
 They must use their analysis to strategically locate 8
strain gages. If the design does not perform as
predicted the team must use load, deformation and
strain data to help them determine what went wrong.
 All teams have to propose the next design iteration
based on test data and additional analyses:
 What must we strengthen?
 Where did we have too much strength?
 Where can we save additional weight?
 How well did the class do? Pretty well! Is it not
amazing what loads can be reacted for this geometry
with a ½ lb of low strength aluminum?
Team
Weight (lb)
Failure Load (lb)
1
0.512
4830
2
0.635
7610
3
0.437
7940
4
0.454
8710
5
0.701
11900
6
0.587
4840
5000
Load (lb) or Strain (S)
4000
Load
3000
Strain 1
Strain 2
2000
Strain 3
Strain 4
1000
Strain 5
0
Strain 6
Strain 8
‐1000
0
0.05
0.1
Deformation (in)
0.15
Matt Hollen
Lashun Oakley
Emily Walker
Load (lb) or Strain (S)
8000
Load
Strain 1
4000
Strain 2
Strain 3
0
Strain 4
Strain 5
Strain 6
‐4000
Strain 8
0
0.04
0.08
Deformation (in)
0.12
0.16
Wenxing Jiang
Ryan Oliver
Jon Worden
10000
Load (lb) or Strain (S)
8000
Load
6000
Strain 1
4000
Strain 2
Strain 3
2000
Strain 4
0
Strain 5
Strain 6
‐2000
Strain 8
‐4000
0
0.05
0.1
Deformation (in)
0.15
Jimmy Kim
Chris Sanchez
Trenton Short
10000
Load (lb) or Strain (S)
8000
Load
6000
Strain 1
4000
Strain 2
2000
Strain 3
0
Strain 4
‐2000
Strain 5
‐4000
Strain 6
‐6000
Strain 8
0
0.1
0.2
Deformation (in)
0.3
Austin Elledge
James Hills
Tyler Haga
8000
Load (lb) or Strain (S)
Vance Golden
Ian Blanski
Thiam Wong
Yahya Alsami
12000
Load
Strain 1
4000
Strain 2
0
Series4
‐4000
Strain 4
Strain 5
‐8000
Strain 6
‐12000
Strain 8
0
0.05
0.1
0.15
Deformation (in)
0.2
0.25
5000
Load (lb) or Strain (S)
4000
Load
3000
Strain 1
2000
Strain 2
1000
Strain 3
Strain 4
0
Strain 5
‐1000
Strain 6
‐2000
Strain 8
0
0.05
Deformation (in)
0.1
Max Di Lonardo
Steve Elliott
Tanner Owens