Backbone Optimization — Tobias Engineering Studios

Backbone weldments are used to hold tooling in a welding cell. In this research, the stresses in current and potential designs for weld-cell backbones were analyzed.

FEA studies for factor of safety, maximum stress and deflection were conducted using SolidWorks Simulation. Total tooling loads from 0 to 4000 lbf in varying configurations were applied to each backbone.

After the initial research, a new design was analyzed. By selecting the new 102” x 24” design with 2” x 2” x 0.25” tube and 0.75” top plates over the old 102” x 36” design with 3” x 3” x 0.25” tube and 0.5” top plates, backbone weight reduced by 32% and total material cost by 18%.

Horiz Orientation.png

Vert Orientation.png

Material Cost.png

102in x 24in Backbone FOS.png

102in x 36in Backbone FOS.png

Weld-Cell Backbone Optimization-01.png

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Weld-Cell Backbone Optimization-10.png

Weld-Cell Backbone Optimization-11.png

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102in x 24in Frame Displacement, 4000 lbf.png

102in x 24in Frame FOS, 4000 lbf.png

102in x 24in Frame Von-Mises Stress, 4000 lbf.png

102in x 36in Frame Displacement, 4000 lbf.png

102in x 36in Frame FOS, 4000 lbf.png

102in x 36in Frame Von-Mises Stress, 4000 lbf.png

Weld Fixtures

Check Fixtures