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.