A few images from the second full scale mock-up…
-1/8″ Aluminum may be excessive in weight for panel + tab connection
-A perforated score @ 1/8″ aluminum is very difficult to bend. Either the panel must be 1/16″ thickness or use a channel notch, which may only allow for 90 degree folds.
-Folded connection is very clumsy looking, may go for a triangular shape as well as cut away most of the back face of the connection b/c the first fold restrict almost all of the force
A few images showing very preliminary FEA analysis.
Axial stress with an aluminum pipe cross section.
Shear stress with an aluminum pipe cross section.
Axial stress with an aluminum “T” cross section.
Shear stress with an aluminum “T” cross section.
-Evenly distributed loading (Inaccurate!)
-Axial & shear loading calculation for 2 cross sections
-“T” cross section appears to resist more loading and force high stress areas to the lower right landing of the surface.
-Provides generic feedback for the surface generation….