ALSTOM Support HM-V4

grabcad

A tube-based support system for structural bodies features sheet metal end plates welded at an angle for enhanced strength. Simple, bendable brackets made from sheet metal are welded along the tube's length, with a ridge added for increased stiffness and strength. This results in a lightweight, yet robust structural member, weighing 120 kg per set and offering a 58% weight reduction. Estimated production cost is €1175, using s275JR steel. Stress analysis reveals overall low stress, with localized higher stress regions near mounts, but an average safety factor of above 4. The design has been optimized for load support and FEA was used to calculate reaction forces accurately. Load combinations were tested to ensure adequate performance under heavy loads, with stresses well below the yield strength. Despite software issues during assembly saving, all mounts were successfully saved and a "design space reference box" created to show compliance with given design limits.