Posted: April 7th, 2015

Design and Technology

Design and Technology

Project description
It is noted that Solidworks Simulation Express has a built in reporting feature. A computer generated report is not suitable for this assignment however, please write your own discussion of your process and include screen grabs where appropriate. Also you must rely on your own engineering knowledge to optimise the model and not use any automated software features.

EAT216 FEA Assignment 2014-2015 Page 1 of 3
Dave Knapton
EAT216 – COMPUTER AIDED ENGINEERING
FINITE ELEMENTS ANALYSIS ASSIGNMENT
BRACKET RE-DESIGN REPORT
This assignment contributes 25% of the overall module marks.
1. INTRODUCTION
Finite Element Analysis (FEA) is a valuable design tool which can be utilized to offer a simulated predication of how complex 3D geometry will perform under certain loading conditions. Design software such as Solidworks can make the task relatively simple but the information given to the software and interpretation of the results requires significant understanding of the application. It is for this reason that a detailed report should accompany such analysis to convey the rationale for the study.
2. ANALYSIS AND DESIGN REPORT
2.1 The Task
Part A
You are to use Solidworks Simulation Xpress Analysis Wizard to analyse the geometry of the bracket as detailed in fig 1. Please pay careful attention not only to the geometry of the bracket but also the installation and loading condition. Please note, you may model this geometry from scratch using the drawing or alternatively use the Solidworks part file downloadable from Sunspace.
You will be awarded marks for Part A as follows:
Appropriate fixtures applied to the model to replicate real life application. 5 marks
Appropriate loads applied to the model to replicate real life application. 5 marks
Application of correct material. 5 marks
A written description to explain the reason for adding the fixtures and loads in the way you did.
15 marks
A written commentary to conclude the results, this should include as a minimum, reporting of the maximum stress and displacement experienced by the component and some analysis of the results with respect to the material yield strength should also be included. 10 marks
Part B
Once this initial analysis is complete, you are to use the results to inform a redesigned bracket and validate this with FEA. The technical performance of the bracket should be the focus of the re-design and thus you do not need to worry too much about other factors such as the manufacturability. A suitable starting target for the re-design should be that you are aiming to reduce the weight of the bracket by 10% minimum, without increasing the maximum deflection by more than 10%. You should not be constrained by these targets however, you may find these easy to exceed or you may find them extremely challenging, the result itself is not such a concern but your documented approach and clear reporting of the findings are of importance. Optimise the bracket to the best of your ability.
The constraints of the redesign are:
1) All fixing points of the bracket must remain the same, size and position.
2) The load bearing face must undergo no modification I terms of size or position.
3) The load itself must be the same size and direction.
The variables you are permitted to change are:
1) The geometry of the bracket.
2) The material of the bracket.
EAT216 FEA Assignment 2014-2015 Page 2 of 3
Dave Knapton
Marks for Part B will be awarded as follows:
Rationale for improvements based on analysis from the initial bracket. 20 marks
Documentation to show that comparable testing has occurred. 10 marks
A conclusion which reports the analysis results of the re-designed bracket compares the results with original. This should include as a minimum, reporting of the maximum stress and displacement experienced by the component. Some analysis of the results with respect to the material yield strength should also be included. 20marks
Accurate documentation of the design changes made. 10 marks
It is noted that Solidworks Simulation Express has a built in reporting feature. A computer generated report is not suitable for this assignment however, please write your own discussion of your process and include screen grabs where appropriate. Also you must rely on your own engineering knowledge to optimise the model and not use any automated software features.
If you adopt an iterative approach and wish to include data from incremental steps, please include these in appendices.
2.2 Report Requirements
Your submission should take the form of a report, not exceeding 8 pages (plus appendices if necessary), and address the items in the above marking scheme.
2.3 Submission Date Your report submission is to be uploaded to the relevant Dropbox on Sunspace by 23/04/15.
EAT216 FEA Assignment 2014-2015 Page 3 of 3
Dave Knapton
Figure 1 – The geometry, installation and loading condition of original bracket.

EAT216 FEA Tutorial 1
FEA Introduction
Introduction
Finite Element Analysis (FEA) will allow you to simulate the actual loading conditions to a design to understand how it will perform. In order to achieve meaningful analysis, the Engineer must understand how the part is loaded, from what material it is manufactured and what loads will be applied. Loads must be defined in terms of magnitude AND direction.
For this module we will use Solidworks SimulationXpress, which can be accessed by clicking on the ‘Evaluate’ tool bar.
The basic FEA workflow is as follows:
1) Model the geometry of the part you wish to analyse ACCURATELY.
2) Define the ‘Fixtures’ for the model.
3) Define the loading conditions for the model.
4) Define the material for the model.
5) Run and review the analysis.
6) Analyse the results.
EAT216 FEA Tutorial 1 – Introduction Page | 2
Please complete the following E Tutorial found within the Solidworks software.
Click Help > SolidWorks Tutorials
Select “Design, Evaluation
and Simulation”
Select “Solidworks SimulationXpress”
Select “SimulationXpress Basic Functionality”
Complete the exercise as instructed.
NOTE: You will be requested to open the following file: <install_dir>samplestutorialcosmosxpressaw_hook.sldprt
Please ensure you save this file once open to avoid losing your analysis.
EAT216 FEA Tutorial 1 – Introduction Page | 3
Using the knowledge gained throughout the above tutorial, apply your new found analysis skills to the following conditions. All dimensions are in mm.
Condition A
Condition B
For the above conditions record the maximum stress and displacement for each loading condition.
Explore the relationship between the maximum stress and the yield strength of the material.

EAT216 FEA Tutorial 2
FEA Replication of Loading Condition
Introduction
The limitation of the examples explored in the previous tutorial is that fixtures and loads can only be applied to an entire face. This is not always what is required as for the most meaningful results; when using FEA tools it is the job of the engineer to understand the true loading condition of a component and to model this in the analysis.
This tutorial will explore how to split a face into smaller ‘zones’, a technique that will be useful in achieving more realistic analysis. We will then move on to considering how best to analyse a pin fixing condition.
As will ALL CAD work, please ensure you save your data regularly to avoid loss of work.
Please also ensure you use SI units throughout.
EAT216 FEA Tutorial 2 – Loading Conditions Page | 2
Please consider the following condition for analysis. All dimensions are in mm.
Condition C
Step 1 – Model the Beam as Shown
Step 2 – Create the following sketch on the BOTTOM face of the beam
EAT216 FEA Tutorial 2 – Loading Conditions Page | 3
Step 3 On the Features tool bar, click Curves > Split Line
Select the sketch created in step 2 and the bottom face. Click OK, the bottom face should now be in 3 sections.
Step 4 – Create the following sketch on the TOP face.
EAT216 FEA Tutorial 2 – Loading Conditions Page | 4
Step 5 – Repeat the ‘split line’ command with the TOP face and the sketch created in step 4.
The TOP face should now be split as shown.
Step 6 – Carry out the loading analysis as dictated in the original diagram, record the maximum stress and displacement.
Displacement
Von Mises Stress Plot
EAT216 FEA Tutorial 2 – Loading Conditions Page | 5
Condition D
We will now analyse a single link from a bicycle chain.
Step 1 – Create a new part and create the following sketch
Extrude the geometry to be 3mm thick.
Step 2 – Add a fixture to one hole and apply a load of 1kN to the other hole so that the link is in tension. NOTE: the material should be Alloy Steel.
BEFORE RUNNING THE ANALYSIS:
Consider what you would expect to happen the link as it deforms and stresses are experienced in the material.
EAT216 FEA Tutorial 2 – Loading Conditions Page | 6
Step 3 – Analyse the results Above is the resulting stree plot for the analysis described above. While you would expect the stresses to be experienced the same at each end. This is clearly not the case. This error is due to the way that one ENTIRE hole was fixed and the load was applied to the ENTIRE hole at the other end.
To alleviate this issue, we need to split the faces on the inside of the holes…
Step 4 Highlight the necessary plane through the middle of hole, click on the spectical icon to show the plane. Create a further plane at a 20mm offset. The result should be two planes passing through the hole centres as shown.
Step 5 Select Curves > Split Line Select the ‘Intersection’ option Select the necessary plane and hole face
EAT216 FEA Tutorial 2 – Loading Conditions Page | 7
Click OK, the face should now be split.
Step 6 Repeat for the opposite end.
Step 7 Redo the analysis as in step 2 but only add a fixture and load to the OUTER MOST faces of the holes.
EAT216 FEA Tutorial 2 – Loading Conditions Page | 8
Step 8 Analyse the results once more, it should show a condition closer to that expected in real life.
Step 9 Modify the geometry of the part to see what material could be removed from the link without increasing the maximum stress significantly.

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