In many mechanical components, stresses do not act in isolation. Tension, compression, bending and torsion appear at the same time. Combined stress simulation makes it possible to understand how the part really responds in service.
Simulating combined stresses in mechanical components
When a component works under several simultaneous loads, simplified calculations leave areas unanalysed. FEM simulation makes it possible to see the joint effect of all loads and detect critical points before manufacturing.
When combined stresses appear
Combined stresses are common in industrial components subject to movement, guiding or load transmission. They usually do not appear in a single direction or in a constant way.
- Structural elements with eccentric loads.
- Shafts and supports with simultaneous torsion and bending.
- Mechanical joints subject to variable load.
Preparing the FEM model
The simulation starts with a model that reproduces real geometry, materials and joints. The boundary conditions represent how the load is transmitted to the component.
The mesh is refined in areas where different stresses converge, since stress concentrations usually appear there.
This type of work is part of the finite element (FEM) calculation services applied to industrial mechanical design.
Simultaneous application of loads
In the simulation, all relevant loads are applied together. The model calculates the real response of the component under that combined scenario.
This makes it possible to see how stresses add up or interact, something that does not show up in separate analyses.
Reading stresses and deformations
The analysis shows maps of equivalent stress and overall deformation. The most heavily loaded areas usually coincide with section changes, small radii or fixing points.
This information is used to make design decisions with judgement and without oversizing the whole component.
Design adjustments after the simulation
With the FEM data, localised improvements are introduced. Small changes usually have a clear effect on overall behaviour.
- Spot reinforcements in stressed areas.
- Improved geometries to distribute stresses.
- Material reduction where it isn’t working.
Validation before manufacturing
After the adjustments, the simulation is repeated to check the new behaviour. The component is validated under real working conditions.
This approach is integrated into innovation mechanical engineering projects, where calculation accompanies design from the start.
Application to assemblies and industrial lines
Combined stress simulation is not limited to isolated parts. It is also used on subassemblies and complete structures.
In projects with greater structural integration, this work is coordinated with civil engineering and industrial BIM.
General information is available at kernova.es.
Frequently asked questions
Why not analyse each stress separately?
Because the interaction between loads can generate stresses that do not appear in isolated analyses.
Does it apply only to new parts?
No. It is also used to review existing components and propose improvements.
Is it valid for heavy machinery?
Yes. It is common for components subject to large loads and repetitive movements.
