Problem & Context
Several assemblies exhibited stress fractures around a bend in a 316 stainless steel sheet-metal baseplate. The objective was to determine whether the root cause was a design deficiency or an external factor such as loading conditions or environmental exposure.
Scope of Work
- Collected service history and lifecycle data for the affected systems to identify operational loads and potential environmental contributors.
- Calculated the worst-case loading scenarios the baseplate might experience over it expected service life to use as input for the finite element model.
Technical Approach
Imported the sheet-metal geometry into PrePoMax and prepared it for analysis: meshing, material definition, and boundary conditions setup.
Conducted a simple linear static stress analysis under the identified worst-case boundary conditions.
Extracted the maximum stress values and compared them with the mechanical properties of 316 SS, using the S-N fatigue curve to assess durability over the component’s life.
Cross-checked simulation results with the physical inspection data to validate conclusions.
Technical diagram or schematic would be displayed here
Results
Project results visualization
The FEA confirmed the as-designed baseplate geometry and material selection were sufficient to withstand expected service loads without failure.
Investigation of maintenance records revealed that several failed parts had been operated for months without the reinforcement plates later added in a design revision. Micro-fractures likely initiated during that period, propagating even after the plates were spot-welded and the parts returned to service.
The analysis ultimately determined that the observed fractures stemmed from pre-existing fatigue damage, not and intrinsic design flaw.