Supporting and the accurate positioning of tooling on a Carbon Dial Table may on
occasion require a INSERT BLOCK to be molded within the Dial structure.
The INSERT BLOCK can be manufactured from several materials. The choice of material
is dependant on loads applied to the tooling.
To provide insight into the different materials available an analysis was performed on a
dowel pin in a hole with a steel insert. INSERT BLOCK materials were FOAM (baseline),
CARBON LAMINATE, STEEL, Mic6 ALUMINUM (Typical Dial Table material), and 6061-T6
Aluminum.
Three axial load cases where considered, 200 lbs, 1000 lbs and 6000 lbs.
Stress Analysis was performed using CompositePro. Factor of Safety analysis was
performed using Maximum Stress criteria. Material Strength properties where degraded
from ultimate for compression fatigue @ 10^6 cycles. ACI degrades material strength
properties further to account for strength scatter, harsh industrial use practises,
temperature and other environmental factors as applicable.
Analysis A - Baseline Foam with no
INSERT BLOCK, steel insert
supporting a fitted dowel pin, axial load
carried by composite skins and foam
core.
Analysis B - Carbon Fiber Laminate
INSERT BLOCK, steel insert
supporting a fitted dowel pin, axial load
carried by composite skins and Carbon
Laminate INSERT BLOCK.
Analysis C - Aluminum 6061-T6
INSERT BLOCK, steel insert
supporting a fitted dowel pin, axial load
carried by composite skins and
Aluminum 6061-T6 INSERT BLOCK.
Analysis D - Aluminum Mic6 INSERT
BLOCK, steel insert supporting a fitted
dowel pin, axial load carried by
composite skins and Aluminum Mic6
INSERT BLOCK.
Analysis E - Steel INSERT BLOCK,
steel insert supporting a fitted dowel
pin, axial load carried by composite
skins and Steel INSERT BLOCK.
ANALYSIS A - Compression Stress State resulting from axial loads shows maximum
compressive stress in the Dial Table Skins and virtually no stress in the foam core. The factor
of safety profile shows the design was adequate for at least 1000 lbs applied repeatably for
10^6 cycles.
HOW TO READ THE DIAGRAMS:
The Diagram on the LEFT is the compression stress diagram for each LOAD CASE. The
x-axis provides the ply number and can be thought of has thro' the dial table thickness. The
compressive stress on the Composite Skins is symmetrical on either side of the core stress
which is central. The Diagram on the RIGHT provides information on the Factor of Safety,
above 1 is considered adequate for the load case.
ANALYSIS B - Compression Stress State resulting from axial loads shows maximum
compressive stress in the Dial Table Skins and compressive stress is showing in the Carbon
INSERT BLOCK. The factor of safety profile shows the design was adequate for at up to
6000 lbs applied repeatably for 10^6 cycles.
ANALYSIS C - Compression Stress State resulting from axial loads shows maximum
compressive stress in the Dial Table Skins and compressive stress is showing in the
Aluminum 6061-T6 INSERT BLOCK with a magnitude similar to that seen for the Carbon
INSERT BLOCK. The factor of safety profile shows the design was adequate for at up to
6000 lbs applied repeatably for 10^6 cycles.
ANALYSIS D - Compression Stress State resulting from axial loads shows maximum
compressive stress in the Dial Table Skins and compressive stress is showing in the Mic6
Aluminum INSERT BLOCK with a magnitude similar to that seen for the Carbon INSERT
BLOCK. The factor of safety profile shows the design was adequate for up to 200 lbs applied
repeatably for 10^6 cycles.
ANALYSIS E - Compression Stress State resulting from axial loads shows maximum
compressive stress in the Steel INSERT BLOCK. The factor of safety profile shows the design
was adequate for up to 6000 lbs applied repeatably for 10^6 cycles.
A compression performance
comparison of INSERT
BLOCKS manufactured from
different materials subjected
to an axial fatigue load.
