Summary
The objective was to design and manufacture a sheet-metal bracket to support a steady upward acting load. The bracket could of only consist of two separate two-force members suitably joined. The main design decision to be made was the choice of the shape of the members and the location of the point at which they are joined.
Process
First, preliminary sketches were made and rough 3D structures were modeled in order to get a sense of the requirements and limitations of the design. We ran Finite Element Analysis through NX CAM to determine ideal geometries of the members of the bracket.
After finalizing our design, we again used FEA to ensure that our bracket could endure the upward load requirement.
We ordered the appropriate sheet metal and manufactured the bracket using bending tools, rivet guns and spot welders.
Result
An apparatus for the load testing was constructed and then used to test the manufactured bracket. At the conclusion of the testing, our bracket was able to withstand more than 200% of the upward load requirement.
Umer Zakaria 