InfraBuild Steel · Jun 2025

Custom Roll Adjustment Spanner

FEA verified tool, design to release, Newcastle Rod Mill

Released with SAP BOM

Problem

Operators adjusted rolls with a tool that forced a poor posture and a high applied load, and no engineered replacement existed.

What I did

Designed a purpose built spanner, verified it by FEA and hand calculation, and took it through the full release including the SAP BOM.

Result

Manual handling risk removed at the source, with a verified, stocked and reorderable tool under change control.

Role	Design, FEA and hand verification, release
Release	Full design to release, SAP BOM
Factor of safety	5, FEA and hand calc

Study	Elements	Nodes	Convergence	Worst Jacobian
Initial geometry	8 193	14 576	0.904%	1.11
Revised geometry	8 382	15 034	0.409%	2.36
Coarse mesh check, h refined once	664	1 516	1.51%	1.96
Interim configuration	8 302	14 783	0.518%	1.12
Released configuration	8 404	14 907	0.567%	1.08