A detailed finite element contact analysis of a sheet metal assembly was completed for a computer server application. The analysis model included detailed modeling for various connectors including line welds, plug welds, spot welds, pop rivets and bolts. The modeling included mechanical locking of the edge-to-edge contact and face-to-face contact in the assembly. The analyses were completed to complete the design process and provided tabulated summaries of the factors-of safety for all key locations in the assembly. A design review provided recommendations for improving durability. A review of physically tested frames provided additional recommendations for data collection during physical tests and modes of failure analysis for the system.
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