Design engineering - OCREnsuring structural integrity

Design engineering is the study of problem solving by ‘traditional’ engineering and design. It applies an understanding of materials, creative design thinking and manufacturing techniques.

Part ofDesign and TechnologyIn-depth technical principles

Ensuring structural integrity

Forces act on materials all the time - even if a material appears stationary it still has a force acting on it. There are five terms used to describe what type of force can act on a material:

  • - a pulling force
  • - a pushing force
  • - forces at an angle to the material
  • - a twisting force
  • - forces acting across the material
Five different forces: Compression; bending; tension; torsion and shear illustrated around a main label saying ‘forces’.

often adapt materials to alter their performance, improving their ability to withstand , and .

For example, a bicycle frame is commonly made up of a number of triangulated tubular pieces, most notable in the classic ‘double diamond’ design.

A double diamond shaped bicycle frame.
Image caption,
The ‘double diamond’ design for bicycle frames

Joints of the frame will often be with additional materials, steel plates are placed at the front where the main frame meets the fork holding the front wheel. This increases the frame thickness to improve its and . The stiffness of a bicycle frame is a measure of how much the frame twists, flexes (torsion) and bends. The of the metal tubes used will affect the stiffness of the frame - the greater the diameter the stiffer the frame. If the frame is not stiff enough, energy will be lost as it will be transferred to the frame (as a twisting force, referred to as torsion) rather than transferred through the wheels.

Another example is the of cardboard - it can be corrugated and sandwiched between flat sheets to make it stiffer and more rigid. The more layers added, the stronger the end result.

A close-up view of rolled up corrugated card in green and brown.
Image caption,
Corrugated card

Steel bar (called ‘rebar’) is used to reinforce to improve its tensile strength and to reduce the amount of bending that occurs.

Wet concrete being poured on a steel reinforcement mesh to form strong floor slabs.
Image caption,
Steel rebar in concrete