EG-264 CAE C2 – SOLIDWORKS Assignment 2021/2022 EG-264 – C2 – SOLIDWORKS Coursework (50%) 2021/22 Turnitin Submission Deadline: 4pm Wednesday 8th December 2021 Assignment – Industrial Loaded Bracket Design Optimisation The assessment for this task will be based on an individual’s report (5 PAGES MAX INCLUDING the Part Drawing (drawing must be A3 in size) – NO appendices, cover page does not count towards page total. Any pages after reaching the page limit will not be marked. This assessment contributes 50% to the final grade of EG-264. The following criteria will be used to assess the reports: 1. Introduction to the overall design task (10 %). 2. Description of the key variables of your design and the reasoning for the design choices that have been made (20 %). (Specifically, why you altered the variables chosen, and how they affect the improved design compared to the initial values and those not altered). 3. Completion of the simulation experiments with results summary (20 %). 4. Technical drawing of optimised design (10 %). – (N.B If the part cannot be manufactured from the drawing, the max mark for this section will be 4%). 5. Conclusion (20 %). 6. Overall quality of report (20 %). Basic Details: For this INDIVIDUAL assignment, a technical report detailing your solution for the optimisation of the design is required. This should be submitted as a single PDF document and submitted through the Turnitin link on Canvas. In the report you should consider (but are not limited to) The analysis of the optimum design for a low cost, low weight and high strength product, but it is NOT to be over/under Engineered (all claims must be backed up with evidence). Demonstration of mesh refinement (before the final 16 simulations). A plot of the von Mises stress results ALONG one edge of the shelf length for all simulations (See Figure 2). A plot of the bracket’s factor of safety for all simulations. A plot of the displacement results ALONG the edge of the shelf length for all simulations (See Figure 2). Consideration of additional design requirements – What temperature can the final optimised bracket design be used in A comparison of the initial to optimised bracket design shown in Figure 3. EG-264 CAE C2 – SOLIDWORKS Assignment 2021/2022 Background: An industrial bracket manufactured from Alloy Steel is used in an industrial environment used in conjunction with other similar brackets, each fixed to a plate on a wall. A shelf lays on the horizontal surface and is attached using three vertical bolt holes (6mm diameter). The mass applied to each individual bracket (acting vertically down) is 110kg ±10%. The brackets are supporting the shelves in a working warehouse, in which there is no air conditioning for the workforce, and so the temperature varies throughout the year. The temperature can reach a high point of 40 degrees Celsius. The selected design cannot fail in service, so a design of experiments (DOE) approach is to be adopted to optimise to a final suitable product. The bracket is to be made as light as possible and MUST NOT be considered under or over engineered. An initial design structure has been generated, and there are several variables that are used to create the initial bracket design as shown in Figure 3, with numerical values stated in Table 1. Table 1: Initial Bracket variables and dimensions V1 Height 140 mm V2 Brace Angle 30 deg V3 Length 200 mm V4 Brace Width 10 mm V5 Width 40 mm V6 Bolt Holes Diameter 6 mm V7 Thickness 3 mm V8 Hole Height 40 mm The bracket is to be fixed in place through the three holes through the back plate of the bracket. The force loading imposed on the bracket is in the normal direction to the top surface of the bracket shelf (Figure 2). The area to which the force is applied on the bracket, is the full width and, the whole top surface to the vertical face (see Figure 2). For this assignment, a structural analysis of the initial bracket must be done, and if the initial bracket is unsuitable for the requirements, a suitable optimised bracket design is to be generated. Considering that the assignment part is an industrial shelf component, where workers will be situated, and that there is a possibility that the working temperature could increase from normal ambient temperatures. This may need co
nsideration during the design process. The final part design choice must evidence, using FEA simulation, meaningful information in terms of being low cost, low weight and of suitable strength. The designer must consider manufacturability and sustainability while using an appropriate safety factor to not be under or over engineered. To help deliver this, EG-264 CAE C2 – SOLIDWORKS Assignment 2021/2022 the designer can vary any FOUR of the control factors (bracket variables), while keeping the remaining variable dimensions as those shown in Table 1. N.B – You will need to explain your reasoning for your choice of variable changes. For optimisation, the variables chosen to be changed in the simulations should consider two levels (high and low) for each of the altered control factors. Design of experiments The Taguchi design of experiments (DOE) method can be used to plan the simulations (table 2). The DOE objectives are to acquire data in a controlled way, obtaining information about the behaviour of the bracket and to also identify significant factors affecting the design when it experiences a force. With 4 control factors being changed, sixteen experiments will simulate and will be used to identify a low cost, low weight and high strength design by investigating the von Mises stress, displacement and factors of safety responses. Table 2: Taguchi L16 Orthogonal Array Design example RUN Control Factors 1 2 3 4 1 1 1 1 1 2 1 1 1 2 3 1 1 2 1 4 1 1 2 2 5 1 2 1 1 6 1 2 1 2 7 1 2 2 1 8 1 2 2 2 9 2 1 1 1 10 2 1 1 2 11 2 1 2 1 12 2 1 2 2 13 2 2 1 1 14 2 2 1 2 15 2 2 2 1 16 2 2 2 2 Description of Task As part of your procedure, you will need to undertake the following tasks to the design provided: Create a 3D model based on assignment drawings. Create a simulation study Define loads and constraints Mesh the model (using curvature based mesh) Run the model and perform a mesh dependency study to ensure correct results. EG-264 CAE C2 – SOLIDWORKS Assignment 2021/2022 Paramaterise the design variables coefficients. Perform a design study varying FOUR of the model coefficients with a low and a high value to obtain the 16 simulation run results. Find the Von Mises stresses and resultant deformations. Plot and compare the stresses and resultant displacements along the edge of the shelf length of the bracket for each scenario generated, along with the determined factors of safety. Is the factor of safety of the model suitable Under or over engineered What temperature increase can the bracket endure Assessment MARKING structure: The assessment for this task will be based on an individual’s report (5 PAGES MAX INCLUDING the Part Drawing – NO appendices). Marks WILL BE LOST if the report submitted is longer than the maximum page limit. The mark that is achieved will contribute 50% towards your final mark for EG-264. The following criteria will be used to assess the reports: 1. Introduction to the overall design task (10 %). 2. Description of the key variables of your design and the reasoning for the design choices that have been made (20 %). (Specifically, why you altered the variables chosen, and how they affect the improved design compared to the initial values and those not altered). 3. Completion of the simulation experiments with results summary (20 %). 4. Technical drawing of optimised design (A3) (10 %). – (N.B If the part cannot be manufactured from the drawing, the max mark for this section will be 4%). 5. Conclusion (20 %). 6. Overall quality of report (20 %). This should be submitted as a single PDF document and submitted through the Turnitin link on Canvas. Timelines The project will start from week commencing 8th November 2021 and all submissions MUST be in BEFORE 4pm on Wednesday 8th December 2021, submitting via the Canvas Turnitin link. Work that is submitted late will be awarded zero marks. Late submission due to certificated illness or extenuating circumstances will be dealt with according to standard procedures. Email: [email protected] EG-264 CAE C2 – SOLIDWORKS Assignment 2021/2022 Figure 1: Basic bracket design Figure 2: Loading and Probe location EG-264 CAE C2 – SOLIDWORKS Assignment 2021/2022 Figure 3: Bracket Layout Drawing (Not a Technical Drawing)