The Regent Engineering Co. Ltd: Structural analysis improves performance and cuts costs

The MTC analyses complex sheet metal under different conditions to discover alternative ways to improve its performance, durability and reduce its costs.

Regent Engineering are an SME manufacturing complex sheet metal. Its established ‘baseplate’ products are in high demand across a range of sectors including infrastructure and automotive.

The Challenge

Regent engaged the MTC to carry out a structural analysis of the baseplate products, to assess their performance and to decrease the manufacturing cost.

MTC’s Solution

The MTC constructed a number of assessments on the baseplate under different conditions and analysed the results to gain the best possible outcome.

Current baseplate products were tested under load conditions experienced in severe gale-force winds.
A range of down-gauged models were also trialled, to assess if different sheet metal materials or a reduction in the sheet gauge thickness was potentially viable as an alternative.

The Outcome

• Finite Element Analysis (FEA) of all the baseplate variants was conducted in Dassault Simulia software. Forces were applied that reproduced the extreme loading conditions upon the baseplates.
• Down-gauged models for several options, trialled under load conditions experienced in severe gale force winds, were within the yield strength of the material. It was identified that a down-grade of sheet metal material or a reduction in the sheet gauge thickness could potentially be implemented to reduce manufacturing costs.
• The MTC and Regent teams worked together, creating a future development plan to validate the analysis through a programme of mechanical testing.

Benefits to the Client

• Effective use of Finite Element Analysis tools, supported by an experienced partner, removes the need for costly prototyping. This saves design and production time and material, reducing costs.
• Fewer design iterations before concept validation means reduced time to market.
• Other benefits include; more innovative design solutions and reduced waste in materials, energy and time.