Evaluation of Load-Bearing Performance and Cost Efficiency in Steel-Welded and Modular Aluminum Rack Structures
Abstract
1. Introduction
2. Methodology and Results
2.1. Assignment Presentation
2.2. Dimensioning and Strength Material Analysis
3. Assembled Rack Structure
3.1. Design of an Alternative Structure Made of Aluminum Bosch Profiles
3.2. Structural Model Made of Aluminum Profiles
3.3. Finite Element Model of Aluminum Profiles
3.4. Boundary Conditions and Loading of the Aluminum Profile Structure
- 1.
- Hexagonal screws M14: connecting the storage to the uprights, Mk = 90 N·m. The resulting axial force is
- 2.
- Screws with a cylindrical head M8: connecting the top plates and the bottom seat plates to the storage frame, Mk = 8 N·m. The manufacturer specifies the maximum force = 7000 N. The resulting axial force will be
- 3.
- Flanged screws M8: used in brackets, connecting the profiles, Mk = 8 N·m. Even though the same tightening torque is used as in the previous case, the screws have a larger seating area due to the different shape of the head, resulting in a lower axial force:
3.5. Results of the Structural Strength Analysis of the Aluminum Profile
3.6. Eigenvalue Buckling (Boss of Stability) of the Aluminum Profile
4. Welded Rack Structure
4.1. Structural Model of the Welded Construction
4.2. Finite Element Shell Model of the Welded Structure
4.3. Boundary Conditions and Loading of the Welded Structure
- Considering the significant weight of the storage, the structure was loaded with its own weight using the “standard earth gravity” function. In the first step, bolt pretension was applied to all bolted joints in the structure using the “bolt pretension” function, which arises due to tightening the joints with a torque wrench. In this case, the known torque value Mk = 70 N·m applied during the tightening of the bolts is used, and the axial force in the bolt is calculated using the formula: [47]
- In the next step, a continuous load of force with a magnitude of F = 30,000 N, acting in the direction of gravity, was applied to the surfaces of the upper plates. This force includes primarily the weight of the welding fixtures when the rack is fully loaded, along with the weight of other structural elements placed on the rack for securing the fixtures (cover plates, seating plates with encoding for recognizing the presence of a specific fixture type, etc.) (Figure 18).
4.4. Results of the Strength Analysis of the Welded Structure
4.5. Eigenvalue Buckling (Loss of Stability) of the Welded Structure
5. Cost Comparison from an Economic Perspective
- (a)
- Assembled variant
- Input materials (Bosch profiles, plates, and fastening materials—bolts, angle brackets, T-nuts);
- Cutting profiles to the required dimensions;
- Welding of the structure;
- Milling parts of the structure—drilling cylindrical recesses into plates for bolts with a cylindrical head;
- Assembly of the structure.
- (b)
- Welded variant
- Input materials (I profiles, Jäkl profiles, plates, and fastening materials—bolts);
- Cutting of semi-finished products to the required dimensions;
- Welding of the structure;
- Milling parts of the structure—the storage (adjusting the top plates and drilling mounting holes);
- Spraying the structure;
- Assembly of the structure.
6. Comprehensive Comparison of Variants and Discussion of the Obtained Results
7. Conclusions
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Calculation Variant | Maximum Displacement Value [mm]/Deviation | Maximum Stress Value [MPa]/Deviation |
---|---|---|
Analytical | 1.802 | 15.151 |
Numerical (shell model) | 1.687/6.38% | 15.552/2.65% |
Numerical (beam model) | 1.851/2.72% | 15.138/0.09% |
Used Profiles | Profile Cross-Section with Dimensions | Cross-Sectional Characteristics | Material |
---|---|---|---|
Bosch profile 80 × 80 L | A = 18.2 cm2 Ix = 132.1 cm4 Iy = 132.1 cm4 Wx = 33.0 cm3 Wy = 33.0 cm3 m = 4.9 kg | ISO: AlMgSi 0.5 F25 U.S. equivalent: AW-6063-T66 | |
Bosch profile 80 × 40 L mm | A = 9.9 cm2 Ix = 63.4 cm4 Iy = 17.3 cm4 Wx = 15.9 cm3 Wy = 8.7 cm3 m = 4.9 kg | ISO: AlMgSi 0.5 F25 U.S. equivalent: AW-6063-T66 | |
Connecting plate 25 × 100 mm | A = 25 cm2 Ix = 63.4 cm4 Iy = 17.3 cm4 | EN: S235JR (STN: 11 375) |
Material Type | Young’s Modulus in Tension E [GPa] | Poisson’s Ratio μ [-] | Yield Strength Re [MPa] | Ultimate Strength Rm [MPa] |
---|---|---|---|---|
AlMgSi 0.5 F25 | 70 | 0.34 | 200 | 250 |
Used Profiles | Cross-Section of the Profile with Dimensions | Material |
---|---|---|
I profile (HEB100) | EN: S235JR (STN: 11 375) | |
Jäkl profile (80 × 80 × 4) | EN: S235JR (STN: 11 375) | |
Top plate (25 × 100) | EN: S235JR (STN: 11 375) |
Material Type | Young’s Modulus in Tension E [GPa] | Poisson’s Ratio μ [–] | Yield Strength Re [MPa] | Ultimate Strength Rm [MPa] |
---|---|---|---|---|
S235JR | 200 | 0.3 | 240 | 360–510 |
Fastening material, strength class 8.8 | 200 | 0.3 | 640 | 800 |
Variable | Description | Variable Value |
---|---|---|
γ | Thread pitch angle | |
Thread pitch value for the M12 screw | = 1.75 mm | |
Φ′ | Friction angle considering the thread profile | |
Coefficient of friction between the nut (or screw head) and the material | ||
Mean thread diameter for the M12 screw | ||
Friction radius | ||
δ | Hole diameter for the screw for M12 | |
Hexagonal dimension of the nut or screw head for the M12 screw |
Construction Variant | Maximum Value of Equivalent Stress at the Given Location [MPa] | Yield Strength [MPa] | Safety Factor [-] |
---|---|---|---|
Welded | 13.5 | 240 | 17.8 |
Assembled | 24.5 | 200 | 8.2 |
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Jakubovičová, L.; Vaško, M.; Synák, F. Evaluation of Load-Bearing Performance and Cost Efficiency in Steel-Welded and Modular Aluminum Rack Structures. Machines 2025, 13, 506. https://doi.org/10.3390/machines13060506
Jakubovičová L, Vaško M, Synák F. Evaluation of Load-Bearing Performance and Cost Efficiency in Steel-Welded and Modular Aluminum Rack Structures. Machines. 2025; 13(6):506. https://doi.org/10.3390/machines13060506
Chicago/Turabian StyleJakubovičová, Lenka, Milan Vaško, and František Synák. 2025. "Evaluation of Load-Bearing Performance and Cost Efficiency in Steel-Welded and Modular Aluminum Rack Structures" Machines 13, no. 6: 506. https://doi.org/10.3390/machines13060506
APA StyleJakubovičová, L., Vaško, M., & Synák, F. (2025). Evaluation of Load-Bearing Performance and Cost Efficiency in Steel-Welded and Modular Aluminum Rack Structures. Machines, 13(6), 506. https://doi.org/10.3390/machines13060506