Comparative Structural Analysis of Stainless Steel Shelving Designs Under Static Storage Loads Using ANSYS Workbench 2024 R1

Abstract

The rapid growth of the manufacturing industry has increased the demand for efficient and reliable storage systems, making the structural strength of iron racks a critical factor in industrial and warehouse environments. This study aims to compare the structural performance of two iron rack designs with different shelf panel configurations, namely a solid flat plate design (Design 1) and a perforated/slat panel design (Design 2), under various static storage loads using ANSYS Workbench 2024 R1. Both designs were modeled in three dimensions using Autodesk Inventor with identical main frame dimensions and Stainless Steel as the material for all components. Finite Element Analysis (FEA) with the Static Structural module was applied by imposing four load variations ranging from 80 kg to 140 kg with fixed support boundary conditions at the rack feet. The parameters analyzed include Equivalent (von-Mises) Stress, Total Deformation, Safety Factor, and Equivalent Elastic Strain. The simulation results show that Design 1 produces a maximum von-Mises stress of 2.6354 × 10⁶ Pa, a total deformation of 9.8967 × 10⁻⁶ m, and an equivalent elastic strain of 1.5243 × 10⁻⁵ m/m, all of which are lower than Design 2, which recorded values of 2.6894 × 10⁶ Pa, 2.6174 × 10⁻⁵ m, and 1.6429 × 10⁻⁵ m/m, respectively. Both designs achieved a Safety Factor of 15, indicating a very high level of structural safety. Design 1 is recommended for applications requiring a flat and stable bearing surface, while Design 2 is more suitable for applications prioritizing air circulation and material efficiency.