Design Simulation Report: Bracket Stress Analysis, FEA Analysis

This report details a finite element analysis (FEA) of a cantilever bracket made of alloy steel, focusing on stress, strain, and deformation under load using Ansys software. The analysis includes determining the bracket's fundamental and natural frequencies, along with maximum stress, strain, and deformation values. The study compares the original and modified designs, the latter involving increased hole sizes to reduce the volume and weight of the bracket. The report provides a comprehensive comparison of the two designs, highlighting the results obtained from the FEA analysis. The modified design's performance is evaluated against specific criteria, including limits on Voin-Mass stress, deflection, and fundamental frequency. The report concludes that the modified model successfully reduces weight and volume while maintaining values within the specified limits, thus validating the design optimization process.

Stress Analysis of Bracket
Abstract
The structural analysis of the Bracket is carried out using Ansys software and
examined the stress, strain and Voin-Mass stress deformation of the same. The
bracket is made of Alloy steel having the following mechanical properties.
Young’s Modulus: 210 GPA
Poission’s Ratio: 0.28
Yield Strength: Tensile 642.28 MPa
Yield Strength: Compressible: 640 MPa
In Ansys the general structural steel is given as the material property and the
mechanical properties are changed as per the given data.
Descriptio
n
Load Direction
Pressure Vertical on
the top
face
Downward
Fixed
Support Nil Hole Position
Table: Load-cases for Structure
analysis
The results indicate that stress and strain of the bracket and the values
of the same are analyzed.As the deformation and stress are well under
the limit, further optimization is carried out by 3D modeling and the FEA
analysis done for the modified model.
 The fundamental frequency of the Cantilever Bracket.
 The natural frequency of the Cantilever Bracket.
 During loading, maximum stresses are observed on the
edge of the bracket. The maximum Strain and principal
strain.
 The maximum stress and principal stress.
 The total deformation and the maximum deformation.
 Voin-Mass stress and strain.
The FEA analysis of the existing design and the modified design is
calculated and compared.

FEA analysis of the Cantilever Bracket;
Summary:
This technical report is about the FEA analysis of the bracket both for the
existing design and the modified design. The main aim of the modified
design is to reduce the volume of the bracket keeping the following
parameter constant and within the limit.
 The vertical and horizontal length of the bracket.
 The Voin-Mass stress should not exceed 300 MPa
 The deflection should not deflect 0.21 mm.
 The fundamental frequency should be within the limit 260 Hz to 400
Hz.
Input Parameters:
3D model of the Structure
 Input geometry of the Cantilever Bracket was provided in
STP/IGS format.
 The weight of the ref plant is around 237 kgs (approx.).
 Finite element model is developed using ANSYS workbench
15.0.
 Natural Frequencies are computed under appropriate
working conditions.
 The fixed position is at the bolting points.
 The loading is done on the top surface of the bracket. The
pressure is uniformly distributed over the top surface of the
bracket.
 Stress analysis of the cantilever bracket is carried out the the
results are compared.

Result Comparison:
3D Model:
Original Model
Modified Design: The Hole size is increased to reduce the volume and the
weight of the bracket.
Meshing:
In both the model fine meshing is done.

Total Deformation:
Existing Design: the deformation is 0.07 mm
Modified Design: the deformation is 0.11 mm which is well within the limit.

Equivalent Stress:
Existing Design: The Voin Mass Stress is 78.173 MPa
Modified Design: Voin Mass Stress 169.25 MPa, which is well within the limit.

Calculation Part:
Annexure-1: Existing Model FEA Calculation
Annexure-2: Modified Model FEA Calculation.
Conclusion:
The Modified Model has reduced weight and volume. The values are well within
the limit and the model is verified.