This year saw Mechsafe’s Matt Rudas deliver the first Vibration & Fatigue Analysis for Engineers workshops on behalf of the Engineering Training Institute Australia. Thanks to all who attended both the first session, and the second, which was added in response to the large demand for the workshop. Due to Covid, the workshops were delivered online via Zoom, but this did not stop great student participation on topics that were obviously of great interest.
The workshop was designed to introduce fundamental concepts of vibration and fatigue analysis to engineers. Vibration topics covered included modal (natural frequency) analysis, response spectrum analysis and vibration analysis of machinery (condition monitoring). The fatigue sessions started by introducing basic concepts such as fatigue life models, mean stress effects, variable amplitude loading, cycle counting and factors influencing fatigue life. The workshop concluded by showing how the main fatigue design codes in use in Australia today, AS4100 and BS7608, should correctly be used in terms of the classification of details, calculations of stress ranges, modifications to S-N curves and environmental considerations.
Once again, Matt Rudas is presenting a one-day workshop on Finite Element Analysis, being run by the Engineering Training Institute Australia. Click here for dates. This workshop was first held in 2018 and proved very popular, being well attended in Perth, Sydney and Brisbane. This year, the workshop is also being run for the first time in Melbourne. Come along to learn from seasoned experts on all aspects of FEA such as model and element type selection, using analysis checklists, working to codes and standards, FEA report writing and, most importantly, error checking and verification of results. Matt also covers the use of FEA in strain gauging, fatigue, impact, non-linear buckling and plasticity analyses.
In other Mechsafe news, we have recently ended the long term strain monitoring at an iron ore port facility in the north-west of Western Australia. Mechsafe spent over a year collecting strain data remotely from Perth with the aim of fine tuning performance of car dumpers, train indexers and wheel grippers at the port’s train unloading facility. Mechsafe carried out detailed numerical analysis of the machines using the gathered strain data to provide feedback on operational changes in real time.
Mechsafe has recently been involved in the engineering certification of a fleet of light trailers for a national trailer manufacturer. In Australia, all trailers with an aggregate trailer mass (ATM) of less than 4.5 tonne must comply with the requirements of the national code of practice Vehicle Standards Bulletin 1, and the Australian Design Rules. Mechsafe has the expertise to certify new and modified trailers using modern computer analysis techniques to ensure the most cost efficient and structurally optimized design is achieved.
Mechsafe Engineering would like to thank all the attendees of the recently held round of workshops on Finite Element Analysis for engineers, as well as the organizers at the Engineering Training Institute Australia (ETIA) – Paul and Joanne. The courses were very well attended by engineers from a broad range of disciplines, and the positive responses to the workshops were much appreciated.
If you attended and would like to receive the models from the practical sessions that were held towards the end of each workshop, please contact ETIA or Mechsafe Engineering.
The workshop is designed to give an introduction to engineering analysis using the Finite Element Method (FEM). Finite Element Analysis (FEA) is now widely used in industry, with most mechanical and structural engineers relying on commercially available FEA software on a daily basis to carry out engineering
calculations. From structural analysis to harmonic response analysis, stress analysis, fatigue crack propagation studies, impact analysis and post-buckling analysis, FEA is a powerful tool, saving time and providing accurate solutions to engineering problems.
However, although users of FEA have often attended courses on the use of a particular software package, not many are familiar with the underlying theory or many software/code independent practical aspects of working with FEA such as model and element type selection, using analysis checklists, working to codes and standards, FEA report writing and, most importantly, error checking and verification of results. This workshop covers all of these topics and thus provides an in-depth introduction to working with FEA.
A practical demonstration session is also included as part of the workshop to present tips and tricks, CAD model simplification and defeaturing techniques, meshing techniques, error sources and how to minimize errors, and model verification strategies.
Monitoring of industrial machinery for loads, stresses and other variables (e.g. temperature, pressure) can provide valuable information for the optimization of operational parameters and to ensure that machines function reliably, without compromising life through overload or misuse. Mechsafe specializes in the provision of monitoring services of critical machinery where SCADA systems have not been utilized. Operational data is collected and monitored and used as feedback to the operator to fine tune the performance of the system based on real data rather than theoretical design outputs.
Monitoring can last anywhere between several days and several months using batteries and solar panels for the provision of power in remote installations. Sensors can be activated, or put to sleep remotely to allow data collection at specific times – for example when new operational parameters are being trialled. Wireless telemetry equipment allows fast installation with minimum site disruptions.
Mechsafe can process collected data in near real time to provide machine kinematic, load, fatigue damage, wear and other data so that machine performance can be optimized for reliable, long term operation. Mechsafe has successfully deployed systems in remote and harsh environments with clear advantages to the clients. Contact Mechsafe to discuss how we can help with your critical machines and equipment.
Mechsafe Engineering staff have extensive experience in the development, detail design and verification of all types of lifting equipment including cranes, hoists, underfloor lifting systems, mobile jacks, screw jacks and building maintenance units. This experience has been gained both throughout Australia and overseas in Germany, Hong Kong and Taiwan. In addition to detail design, Mechsafe engineers have been involved in fatigue testing, technical specification, project management, procurement, installation and commissioning.
Mechsafe Principal Engineer, Richard Rudas, has previously worked as designer for several crane manufacturing companies in Perth, and designed the Building Maintenance Unit crane for the Central Park Tower in St Georges Terrace. He also worked on numerous rail maintenance lifting equipment projects including the Claisebrook maintenance depot for Transperth, and various locomotive maintenance depots for Queensland Rail.
These specialized engineering design skills, coupled with our expertise in fatigue, engineering critical assessments and fitness-for-service assessments, have recently allowed us to broaden our range of services to include crane inspections. However, Mechsafe can provide more than just function, limiter, indicator and other typical basic crane inspection tests; we have the in-depth design know-how to provide engineered repair and remedial solutions and re-rating calculations to damaged or changed-operation equipment.
Contact Mechsafe to arrange a discussion on the inspection and engineering requirements for your crane assets.
It has been a busy time since the last news post. In its first year of business, Mechsafe has successfully delivered a large range of diverse projects. We invite you to visit the new projects page on our website for information and photos of some of the more interesting and challenging projects completed.
Fracture mechanics is often thought of as being related to the imminent failure of equipment containing cracks through brittle fracture. But the information that a fracture mechanics assessment can yield is a whole lot more than just a critical load, or a critical crack size, that is predicted to cause catastrophic failure.
Mechsafe Engineering is Perth, Western Australia’s newest specialist engineering consulting firm. We are a seasoned and talented team of engineers – our analysis methods are complex but our goal is simple: we want to help you obtain the best design for – and life from – your mechanical structures and equipment. We offer general mechanical and structural design and verification services, however we specialise in the following main areas:
general and advanced structural and mechanical analysis using finite element method (FEA) and boundary element method (BEM) analysis
fatigue, weld fatigue, fracture, fatigue crack growth and failure analysis
engineering critical and fitness-for-service assessments
pressure vessel and storage tank design
strain gauging and condition monitoring
reliability, availability and maintainability analysis
cathodic protection and corrosion analysis using boundary element method (BEM) analysis
We serve the construction, mining, oil & gas, processing, railway, aerospace, defence and marine industries and we look forward to assisting you with your next project.