Topology Optimisation
Advanced FEA techniques helps minimise the mass of an electrical enclosure whilst retaining strength.
Introduction
Our client was struggling to achieve weight targets for their panel whilst maintaining structural integrity. We used topology optimisation to remove unnecessary material from the electrical back plate, providing a stiffer structure with lower weight.
The customer.
The customer was a second tier supplier, providing rugged electrical enclosures to DEF STAN 0035 for military vehicles. We were approached to help reduce system mass whilst meeting the project requirements.
The Problem
A heavy panel, a challenging weight limit.
A relatively simple panel presented a large challenge - a challenging weight limit. Our customer had designed a traditional electrical panel consisting of machined components and a sheet metal chassis.
However, the panel was overweight. Work was required to meet the extreme shock levels stipulated in DEF-STAN 0035 whilst meeting the weight limit.
Our Process
Topology optimisation for weight reduction
We used the advanced finite element analysis of topology optimisation to map the critical load paths through the panel when subjected to certain shock loads.
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This technique highlighted low-stress areas of the structure, which could be thinned or removed to eliminate weight from the panel.
The Solution
A reduced weight solution
The end solution involved a custom machined component designed to most efficiently withstand the shock loads in the design, passing through testing first time.
The Results
The customer hit their weight target and passed shock testing, resulting in a prompt delivery of their system to the end user.
15%
panel mass
reduction
Pass
shock tests first time
