Predicting the maximum safe load for a new sheave wheel design Challenge The client wanted to investigate a new sheave wheel design to determine the maximum working load and write a test specification for safe manufacture. Solution CEAD applied finite element analysis (FEA) tools to analyse the sheave wheel and determined the maximum working load. The FEA results were validated with practical testing of a prototype. The simulated and practical results were then combined to inform development of a test specification. The work gave the client confidence to begin manufacture of their new product. Details The client provided CEAD with a CAD model and materials data of the new design. The CAD model could then be analysed using FEA software to simulate the stresses induced by different loads. The maximum working load was determined by considering both failure and fatigue due to the application of the sheave wheel. A prototype of the sheave wheel was built and tested. The predicted maximum working load was found to correlate well with the practical load. As well as predicting maximum working load, the finite element analysis was used to identify the most likely points of failure for the given design. This insight could then be applied to develop a test specification for the client to ensure safe manufacture of the new product.