SOLIDWORKS Simulation: A Technical Investigation into a Viral Video
A surprising structural failure sparks curiosity and prompts a detailed investigation using SOLIDWORKS Simulation into the potential causes of breakdown.
As engineers, we’re hardwired with a unique trait: the inability to ignore a good mystery, especially when it involves something breaking down unexpectedly. For me, seeing a “look, this failed” post on social media immediately draws me into investigation mode. I can’t help but wonder—not just how it failed, but why. Was it a design flaw? An unexpected environmental load? Should it have failed at all? Is this the failure mode I would have expected?
Recently, I stumbled upon a short video clip of the above showing a minor structural catastrophe. While others might have laughed and scrolled past, I saw a mystery that needed solving. The challenge wasn’t just in uncovering what went wrong; it was understanding all the factors behind it. What began as a simple video quickly turned into a technical deep dive using the power of SOLIDWORKS®.
The Challenge of Complexity: When Hand Calculations Fall Short
Once I had the general problem scoped out, my first instinct was to start with hand calculations. In engineering, our tools range from quick back-of-the-envelope math to elaborate spreadsheets and sophisticated simulations. When faced with these classic arches, however, traditional calculations quickly reached their limit. The structure involved curves and chamfers; not just flat, uniform surfaces. Fluid flows and structural forces interacting with such complex shapes create a puzzle that can’t be solved with basic flow or stress equations.
For an engineer, this kind of complexity is both a challenge and an opportunity. It’s a chance to dig deeper, apply specialized tools, and ultimately seek the cause behind a failure. Knowing that manual calculations wouldn’t suffice, I turned to a combination of photogrammetry techniques and SOLIDWORKS to bring my investigation to life.
Reconstruction: From Photos to Parametric Model
Rather than guessing the structure’s actual dimensions, I used photogrammetry, a technique for extracting 3D information from photographs. In this case, I didn’t have any still images, but I had something even better: a brief walk-around video packed with hundreds of still frames. Photogrammetry applications leverage the common elements across individual frames to build a 3D motion map of the camera’s path, and from this data, algorithms effectively reconstruct the object in virtual space.
Photogrammetrically reproduction based on THIS VIDEO uploaded by Chris Higa to YouTube
Using this technique, I generated a rough forensic map. My result was an *.OBJ model with reasonable fidelity, capturing the crushed car and most of the sign. Combined with bumper-to-bumper measurements of the car, I constructed a detailed parametric model of the structure in SOLIDWORKS, ensuring the model’s proportions were as accurate as possible. This approach allowed me to analyze the structure in realistic conditions without the need for precise field measurements.
Flow Simulation
Using SOLIDWORKS Flow Simulation, I set up a model to replicate high wind conditions around the structure based on meteorological reports from the day of the accident. Flow simulation alone can reveal how air moves over and around complex shapes, providing key data on areas of high and low pressure, including the surfaces of the signage. From this pressure data, it can also track the amount of force exerted on these surfaces.
While unrelated to this study, a flow simulation can provide a host of other information. For instance, one interesting property for a sign designer could be the acoustic power level (audible volume of the flow) downstream from the sign’s flow disturbance—important to ensure that bystanders are not affected by the sound of the trailing turbulent flow.
The Impressive Part
Here’s the cool thing about SOLIDWORKS: It isn’t just a single software tool; it’s an entire ecosystem built to streamline complex design problems and tackle engineering analyses.
After running the flow simulation, I could seamlessly transition to a finite element analysis (FEA) to dive deeper into how wind-induced forces impacted the structure’s integrity. With a quick “Export Results to Simulation” SOLIDWORKS did the heavy lifting, processing the pressures and allowing me to map these “flow effects” as a load on the solid bodies. This was completed far more quickly and far more accurately than if I had simply pulled net forces from the Fluid Flow Simulation. This streamlined process helps engineers make well-informed decisions faster, with each stage of analysis building directly on the previous one.
This workflow enabled me to validate my initial theories, as the results confirmed that the base of the post behaves much like a cantilever beam and would indeed experience the greatest stress at the actual failure point. However, the analysis revealed that wind-driven loads alone were insufficient to account for the failure.
Key Findings and Observations
The results were clear: based on our reverse-engineered dimensions and anticipated materials, the combined simulations predicted a design factor of safety (FOS) at approximately 5:1. While we have not performed a transient (time-dependent) study to account for more complex flow and potential structural harmonics, our initial results generally indicate that the structure had a sufficient factor of safety to withstand normal conditions, even on a windy day.
It was a perfect example of how real-world performance doesn’t always align with design intent.
So, what was the real culprit? Why did this system fail? Without an actual inspection of the failure, it isn’t possible to say for certain but given that the square steel tubing was embedded directly into the parking lot, crevice corrosion is a likely suspect. Crevice corrosion occurs from trapped pockets of water, where surface coatings degrade at an accelerated rate from immersion. Once the underlying steel is exposed to water, it oxidizes (rusts) in that localized area at a highly accelerated rate. From the source photos and videos, it’s evident that a substantial portion of the tubing wall was degraded, resulting in a vastly weakened structure.
Concluding Thoughts: Why Curiosity Matters
As engineers, it’s in our nature to ask questions and dig deeper. Each question is an opportunity to learn, each problem an opportunity to adapt, and both provide opportunities to improve. The combination of curiosity and the right tools, such as SOLIDWORKS, enables us to approach even the most complex problems with confidence. Engineering is about more than just designing and building; it’s about understanding the principles behind why things work—or, in this case, why they do not—and applying that knowledge in the future.
Throughout this study, I was reminded of how powerful SOLIDWORKS can be in tackling real-world engineering problems. Computational fluid dynamics and FEA tools allowed me to quickly transform an idle inquiry into an investigation with reasonably definite results, despite the limited amount of information available.
So, the next time you come across a social media mystery, ask yourself: What forces might be at play here? Could this be prevented? With tools like SOLIDWORKS at your disposal, you have the power to turn these failures into valuable engineering lessons.
Engineering Disclaimer
The content of this blog post is for informational and educational purposes only and does not constitute professional engineering advice. The methods and software tools described are intended to illustrate potential applications of SOLIDWORKS software in engineering analysis. Actual conditions, project requirements, and environmental factors may vary, and this example may not directly apply to your specific projects or use cases.
This blog post includes an analysis referencing iconic signage having a double-arch structure. This structure was reproduced for analytical commentary and educational purposes. This analysis is not affiliated with, endorsed by, or associated with McDonald’s Corporation. The McDonald’s name and iconic arch design are trademarks of McDonald’s Corporation, and all related intellectual property rights remain the property of their respective owner.
Before applying any analysis, techniques, or using SOLIDWORKS software for structural or fluid simulations, consult relevant engineering standards and guidelines. Always verify your results with appropriate testing and professional judgment and seek expert consultation for critical or safety-related projects. The author does not assume liability for the use of information contained in this post.