This was a straightforward model using solid elements,
but care was needed at the “kiss-offs” which joined the
top and bottom surfaces. Our FEA
showed stresses which exceeded the material strength.
Our consultants were able to reduce them to a certain
extent by altering a critical radius, but not sufficiently
to make the trail design work properly.
Our consultants then produced several trial designs and
conducted a short study to find the best strategy. Our
consultants recommended a new approach using radial ribs
incorporated into the rotational moulding. Our customer
quickly turned this into a new detail design and FEA
showed adequate performance to meet the design requirement.