Monthly Archives

June 2011

FEA and Mast Design

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The first part of the process is to come up with an overall rig layout within the rules.  This will assist determining the overall mandrel geometry.

Choosing a one piece mast with no sleeving means that specific patching will be incorporated into the laminate for high load areas, reducing hard points and stress raisers.

 

Pattern design

We then generate a stiffness profile to suit the mandrel geoetry and mast layout.

Pattern design, optimises the laminate thickness vs stiffness vs toughness.

Patterns go direct from engineering to production floor winding machines, minimising human error.

FEA

With FEA models built to replicate the laminate schedule,  a number of “What if” scenerios can be run to determine various bend profiles.

This provides sailmakers and sailors with an option to choose their preferred stiffness as well as bend characteristics.

Model Vs Actual

Final step in the first article is to confirm actual results vs modelling.

With over 25,000 tubes made, the model predicts the bends within +-1%

Quality control reports show that the bend profiles of all masts are repeatable within +-2%

 

 

Rigged mast will be in the boat next week !

One Piece Masts for 16’s

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Design and build mandrel

One piece mast was chosen to increase stiffness (for a given weight)  as well as create an even bend curve (no flat spots). Over the last two weeks the mandrel was designed and manufactured in house, using SolidWorks and our CNC lathes.

Material selection

Quality performance Japanese fibre used to produce 16′ skiff masts. Using our Instron testing machine, fibre coupon testing is performed to validate carbon suppliers data and quality. There is often a large variation between carbon fibre suppliers.

Quality Control

All tubes and masts produced run through the CST MES (Manufacturing Execution System), this monitors all aspects of production to guarantee quality supply.

Bend testing is completed to confirm actual results vs modelling