Strength assessment and structural optimisation

The objective is not merely to assess the strength of a component detail; we aim to analyse and optimise the structural integrity of the entire system.

Strength assessment and optimisation is one of the absolute core competences of the IAMT Group. Having accumulated more than two decades of experience, IBAF assumes responsibility for the development of construction and mining machines, materials handling equipment, storage systems and plant facilities, from the engineering calculations during development to documented final strength verification in full compliance with specified standards and codes of practice.

Range of services

  • In-process computational engineering for strength assessment and structural optimisation
  • Final strength, damage and stability verifications
  • Integrated system simulations including control arrangement, with component load analysis
  • Evaluation of suitability for service through rigidity, vibration and deformation analyses

The simulation tools (analytical, matrix structural analysis, FEM, MBS, FEMFAT®) are selected according to requirements and with a view to achieving maximum efficiency.


Development-related calculations and analyses

Structural optimisation can be more readily attained where the development work is accompanied at an early stage by the appropriate engineering calculations and analyses. Efficient models need to be developed, computed, effectively evaluated and structurally optimised within a short time through appropriate iteration steps. Our approach encompasses the following: 

  • Efficient substitution modelling for complex connecting and interface elements such as bolted joints, antifriction bearings, elastomer mounts – with accurately tailored degrees of simplification  
  • FE model structures with simple local adaptability to structural design upgrades
  • Algorithmic evaluation tools with full validation for fast strength assessment of the integrated assembly in accordance with accepted standards and codes of practice (e.g. FKM guideline for analytical strength assessment of mechanical components, German standard VDI 2230)

Final verification

Whether for documentation purposes, expert assessments, approval or certification, the final as-manufactured status also needs to be fully validated. For this, we offer a range of services, including: 

  • Completely documented strength verification analyses in accordance with e.g. the FKM guideline for analytical strength assessment of mechanical components
  • Verification according to industry- and component-specific standards and regulations such as DIN 15018, EN 13001, EN 13979, EN 12663, EN 13749, Germanischer Lloyd
  • FEMFAT® damage analyses using load time series •Compliance with e.g. German waste handling and landfill regulations DBE and BGE

Integrated system simulation with component load analysis

Not every component in a machine or mobile plant structure experiences the same stresses. The different situations and loading patterns that occur at the local level are critical to design success. However, as the number of positions and the magnitude of the internal dynamics increase, we move on to the whole-system simulation approach in order to derive individual component loads. This enables each component to be individually assessed, but with considerable reduction in the number of load cases that have to be verified. Depending on the structure and operating conditions, the following methods may be employed:

  • Matrix structural analysis (MSA) modelling with definition of all the positions and load case combinations
  • Model-based multi-body analysis (MBA) with definition of the masses and flexibilities relevant to dynamic behaviour
  • Coupled simulations taking into account further subsystems such as hydraulics and the control arrangement
  • Evaluation and verification of fitness for purpose

Evaluation and verification of fitness for purpose

Strength is not always the primary challenge. Particularly in the case of lightweight constructions involving high-strength steels or where geometries have been structurally optimised, phenomena such as stiffness, vibrational behaviour or deformation behaviour may be the key variables. Consequently, we offer:

  • Stiffness analyses  
  • Modal and frequency response analyses
  • Deformation analyses including algorithmic shape and position change analyses