A Simple Lab Project Integrating Theoretical, Numerical, and Experimental Stress Analysis

Learning is enhanced when students consider problems from different perspectives. Unfortunately, in stress analysis courses, the depth of the mathematical analysis and limited time and resources often restricts the focus to traditional closed-form solutions occasionally supplemented with simple demonstrations. In order to enhance student engagement and understanding, a lab mini-project was developed for teaching Castigliano’s method for structural analysis in a stress analysis course. The mini-project consists of a design evaluation task which is investigated using three different methods: closed-form analysis, finite element analysis, and simple model build and test. The task is to select the better of two alternative support structures for a heavy-duty material-handling conveyor belt. Acceptance criteria in the form of maximum deflection and stress are provided. The closed-form analysis is conducted using Castigliano’s method. Beam and shell finite element models are built and analyzed in Abaqus CAE. Structural prototypes are constructed with PASCO Structures System components and tested with simple weights and scales. The strengths of this combined approach are that the students (a) gain experience with the thre