How much more weight can a sheet of aluminum carry in comparison to a sheet of wood?

jelovich

Junior Member
Feb 4, 2021
1
0
6
I am designing a cargo rack for a bicycle in my engineering class, and I am stuck on the testing procedures. I need to ensure my prototype meets all the criteria, but my prototype is made of wood and my final design is made of aluminum. My final design must be able to hold 50 lbs of weight, but I know my prototype won't. Can someone help me figure out the calculations I would need to determine how much weight the wood (5 mm poplar plywood) would need to hold for the aluminum to hold 50 lbs? Is it proportionate?
 

mindless1

Diamond Member
Aug 11, 2001
8,193
1,495
126
There are far too many unknown variables than merely 5mm poplar plywood vs "sheet aluminum", and to put it concisely, their different properties have different failure modes, reshaping potential, and fastening requirements.

I find it hard to believe that you are in an engineering class but did not see the significance of mentioning some particulars about the design as well as type of aluminum and gauge or thickness.

What is this "sheet of aluminum", exactly? Even if you used a metal brake to bend it "some", it would be difficult to get more than one or two bends when you could be aiming for something tubular (hollow) for high strength to weight ratio.

I take that back, you could construct a sheet metal shelf and then it depends on your resources to bend it, but this is a poor strength to weight and cost ratio, but perhaps the easiest way to DIY get the job done. In that case it depends quite a lot on how many bends you put in it, which depends quite a lot on what the metal brake is capable of since you don't have a way to die press them to an optimal shape... OR perhaps you do! A shop hydraulic press, and a die made out of hardwood, could be sufficient if there is significant surface area to work with, to make more intricate shapes than a metal brake alone could do, or I may be barking up the wrong tree if you already assumed you'd be welding separate pieces together.

Since this suggests that the problem is manufacturing rather than potential material strength, I'd shoot for about 2mm thick aluminum in a fairly effective design and thicker 3mm+ for something where you can't fasten or bend a more complex shape. Keep in mind that you can use as thick as your metal brake can bend, then drill it out to reduce weight later. This will be an expensive loss of material, but in a real manufacturing environment, the scrap metal has value rather than going into a landfill.

Hollow round or oval would be best for that but introduces additional challenges in connecting the pieces unless you are adept at welding aluminum, well enough that the welds do not become the weakest part of the design, and they may still be and reach the target goal but it's something to consider.

Square or rectangular tubing will be easier to connect using fasteners and is a bit more forgiving than wood at suffering shock damage, but will also eventually suffer fatigue from it so it is something to consider, that it not just support 50lbs but for how long in a real world use.

I could go on and on but ringtail has it right, that you need to do some testing of the specific material you intend to use, then change materials or design if inadequate. Change materials doesn't mean don't use aluminum, but rather stating aluminum is like stating wood, a material alone does not tell much of the story.

Backing up a bit, apples to apples, if you have 5mm thick plate aluminum in exact same design as wood (except the fastening method may differ), it should have no problem supporting 50lbs, is quite overkill in weight and expense rather than using much thinner tubular structural members as mentioned above, or a framework of solid core round pieces if you can weld it. The size that the platform needs to be, may determine whether solid core or hollow has the most merits.

What if you just keep your wood prototype as a core, then slap some fiberglass on it?
 
Last edited:

mikeford

Diamond Member
Jan 27, 2001
5,670
160
106
Dominant factor is going to be how is the sheet mounted to the frame, by the tip of one corner vs continuous weld all around the perimeter. Bike rolling on a smooth surface, vs pothole, speed bump, etc.
 

mindless1

Diamond Member
Aug 11, 2001
8,193
1,495
126
^ Too little info provided, but being a "cargo rack", the typical method is it slips around the seat tube or stay, held on by bolts there, or a clamp around the seat post, and has vertical support from the portion that goes down to the axle nuts, or clamps very low on the seat stays if a more universal mount design.

No welding, just bolt on. This works fine for the average cargo rack you buy off the shelf.
 

mikeford

Diamond Member
Jan 27, 2001
5,670
160
106
I'm talking about how the sheet is supported, the sheet to mount connection is the primary factor in load capacity.

What is missing here is every known aspect of engineering and design. Static weight won't be the failure mode, it will be dynamic force, so compliance may be the most important aspect of the design.

Without reading minds, maybe what the assignment is about isn't a product as much as properly setting up the equations, otherwise its more a craft project than engineering.
 
sale-70-410-exam    | Exam-200-125-pdf    | we-sale-70-410-exam    | hot-sale-70-410-exam    | Latest-exam-700-603-Dumps    | Dumps-98-363-exams-date    | Certs-200-125-date    | Dumps-300-075-exams-date    | hot-sale-book-C8010-726-book    | Hot-Sale-200-310-Exam    | Exam-Description-200-310-dumps?    | hot-sale-book-200-125-book    | Latest-Updated-300-209-Exam    | Dumps-210-260-exams-date    | Download-200-125-Exam-PDF    | Exam-Description-300-101-dumps    | Certs-300-101-date    | Hot-Sale-300-075-Exam    | Latest-exam-200-125-Dumps    | Exam-Description-200-125-dumps    | Latest-Updated-300-075-Exam    | hot-sale-book-210-260-book    | Dumps-200-901-exams-date    | Certs-200-901-date    | Latest-exam-1Z0-062-Dumps    | Hot-Sale-1Z0-062-Exam    | Certs-CSSLP-date    | 100%-Pass-70-383-Exams    | Latest-JN0-360-real-exam-questions    | 100%-Pass-4A0-100-Real-Exam-Questions    | Dumps-300-135-exams-date    | Passed-200-105-Tech-Exams    | Latest-Updated-200-310-Exam    | Download-300-070-Exam-PDF    | Hot-Sale-JN0-360-Exam    | 100%-Pass-JN0-360-Exams    | 100%-Pass-JN0-360-Real-Exam-Questions    | Dumps-JN0-360-exams-date    | Exam-Description-1Z0-876-dumps    | Latest-exam-1Z0-876-Dumps    | Dumps-HPE0-Y53-exams-date    | 2017-Latest-HPE0-Y53-Exam    | 100%-Pass-HPE0-Y53-Real-Exam-Questions    | Pass-4A0-100-Exam    | Latest-4A0-100-Questions    | Dumps-98-365-exams-date    | 2017-Latest-98-365-Exam    | 100%-Pass-VCS-254-Exams    | 2017-Latest-VCS-273-Exam    | Dumps-200-355-exams-date    | 2017-Latest-300-320-Exam    | Pass-300-101-Exam    | 100%-Pass-300-115-Exams    |
http://www.portvapes.co.uk/    | http://www.portvapes.co.uk/    |