EAT216 - Finite Element Analysis: Bracket Analysis and Design

This report details a Finite Element Analysis (FEA) of a bracket, focusing on its design and performance under load. The analysis utilizes the Von Mises stress method to evaluate stress distribution and potential failure points in a 1060 aluminum alloy bracket. The report explains the simulation setup, including material properties and loading conditions, and interprets the results to determine maximum and minimum displacement and stress values. The findings indicate favorable conditions under the applied load, with suggestions for design improvements through analytical solutions and optimization of applied forces to enhance the bracket's mechanical strength and reduce the risk of fracture. The report emphasizes the importance of FEA in predicting material behavior and optimizing designs for various engineering applications.

FINITE ELEMENT ANALYSIS
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Table of Contents
2. Setting up the simulation.............................................................................................................3
3. Interpreting the results.................................................................................................................4
4. Improving the design...................................................................................................................8
Reference list...................................................................................................................................9
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2. Setting up the simulation
1 (a)
The bracket is used for holding and lifting several engine blocks and assembles components in a
systematic way. It includes optimization and prediction of the bracket through eliminating
potential issues and problems to make sure design of bracket can be improved. The major
application of fixtures in real life is reducing impact of axial and tensile load on a material.
1 (b)
Finite Element Analysis (FEA) is one of the effective and reliable ways to analyze the impact of
forces on the material to make sure risk of failure can be reduced. Von Mises stress method has
been used in understanding maximum and minimum value of stress to determine the yielding
strength of material (Ijirst.org, 2019). The major application of FEA is reduction of failure or
fracture by eliminating adverse effect of forces and optimizes applied force that eventually
increases the yielding strength of material.
2)
1060 Aluminum alloy is an alloy based alloy that is used for bracket that help in reducing risk of
failure or fracture. It is very similar to 1050 aluminum alloy with difference coming down to
0.1% aluminum by weight (Oaji.net, 2019). This material is effective in optimizing axial and
tensile force that improved the mechanical strength of model. On the contrary, aluminum alloy
has low mechanical strength as compared to significant alloyed metal that can be strengthen
through cold working method rather than heat treatment. This material is composed of different
chemical composition such as
 Silicon: 0.25% max
 Titanium: 0.03% max
 Vanadium: 0.05% max
 Copper: 0.05% max
 Iron: 0.35% max
 Magnesium: 0.03% max
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3. Interpreting the results
The simulation design of bracket clearly defines the dimension and loading condition of material
that is 1060 aluminum alloy that facilitates in reducing risk of failure. Von Mises Stress method
has been used to understand the maximum and minimum stress exerted on the material. It also
helps in determining yielding or fracture value of specific material under different loads
condition. The force of 45N is transferred into this component through internal surface of the
bracket (Simscale.com, 2019). However, fixture helps in holding and locating a work piece
during manufacturing operation.
Maximum displacement experienced by the model
The maximum displacement experienced by the model is 0.066 by giving a force of 45N that
clearly implies that material is under favorable condition. The maximum displacement is asserted
on the internal surface of bracket at which force is applied (Azom.com, 2019). The yielding
strength of aluminum alloy plays a crucial role in preventing model from risk of fracture.
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Figure 1: Results of DISPLACEMENT for the simulation of the Bracket
Minimum displacement experienced by the model
The minimum strength exerted on the model is 0.000 at the tip of the fixture where material
experienced the least force (Papageorgiou et al. 2016, p.411). Fixture is an essential element of
production processes that is mostly for automated processes such as inspection, assembly
operations and manufacturing.
Maximum stress experienced by the model
The maximum stress exerted on the model is 29.954 at the back side of bracket near fixtures that
asserted that yielding strength of aluminum is high. On the other hand, the direction of stress is
downward that increase the level of stress on the martial, which is total bear by the fixture.
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Figure 2: Maximum stress on the material
Minimum stress experienced by the model
The minimum stress experienced by the model is 0.020 at the bottom surface of bracket that
implies that the strength of this material can be maximized. The risk of fracture is minimum at
this point that improve the feasibility and reliability of design (Bathe and Zhang, 2017, p.514).
The electrical and chemical composition of aluminum increases the feasibility and reliability of
simulated design with the help of Von Mises Stress method.
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Figure 3: Minimum stress experienced by the model
Von Mises stress method helps in developing an effective and reliable design by understating the
yielding strength of material. The major advantage of finite element analysis through 3D
modeling is reduction in effect of potential risks. The major purpose of Von Mises stress is to
understand the impact of several forces on material. It also facilitates in predicting yielding of
materials under complex loading. Apart from Von Mises Stress, maximum and minimum stress
can be determined that make the assembly process simple and feasible. The maximum stress is
referred to yielding strength of a material that gets failed if the level of force gets increased. The
3D geometry of bracket facilitates in analyzing significance of each force on the material that
eventually improve the installation and simulation of design properly (Salonitis et al. 2017,
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p.2689). The implementation of Von Mises Method helps in developing an effective design by
considering yielding strength of material that is 1006 aluminum alloy vigilantly. This approach
allows engineer to reduce adverse impact of tensile and axial load that also reflect on feasibility
of research.
4. Improving the design
The Von Mises Stress method has been used in developing design of bracket by analyzing the
impact of applied stress on material. The design of bracket mainly focuses on mechanical load
experienced by model that reflects on its yielding strength. The design for the bracket can be
improved by two different ways, which have been listed below:
Applying analytical solution to design
Analytical solution is an effective and reliable way to reduce the risk of failure by analyzing all
mechanical properties of material such as tensile strength, yielding strength, stress and strain.
These properties help in developing better and effective design that reduces the risk of fracture
and failure (Belhocine and Ghazaly, 2016, p.258). Hence, this approach will facilitate in
improving feasibility of design by determining critical point of failure.
Optimization of applied force on model
This approach to design helps in reducing adverse effect of applied forces that eventually reduce
the risk of failure or fracture of material. The best way to optimize the force is determining
principle stress so that most effective material can be used for strengthening the yielding strength
of material. The great advantage of this approach is maintenance of yielding strength of material
at different strength. Therefore, this approach will help in producing most reliable design of
bracket by simplifying complex load vigilantly.
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Reference list
Azom.com (2019), Finite Element Analysis, Available from: [Accessed 28 July 2019]
Bathe, K.J. and Zhang, L., 2017. The finite element method with overlapping elements–a new
paradigm for CAD driven simulations. Computers & Structures, 182, pp.526-539.
Belhocine, A. and Ghazaly, N.M., 2016. Effects of Young’s modulus on disc brake squeal using
finite element analysis. Int. J. Acoust. Vib, 21(3), pp.292-300.
Ijirst.org (2019), Finite Element Analysis, Available from: [Accessed 28 July 2019]
Oaji.net (2019), Finite Element Analysis, Available from: [Accessed 28 July 2019]
Papageorgiou, S.N., Sifakakis, I., Keilig, L., Patcas, R., Affolter, S., Eliades, T. and Bourauel,
C., 2016. Torque differences according to tooth morphology and bracket placement: a finite
element study. European journal of orthodontics, 39(4), pp.411-418.
Salonitis, K., Chantzis, D. and Kappatos, V., 2017. A hybrid finite element analysis and
evolutionary computation method for the design of lightweight lattice components with
optimized strut diameter. The International Journal of Advanced Manufacturing
Technology, 90(9-12), pp.2689-2701.
Simscale.com (2019), Finite Element Analysis, Available from: [Accessed 28 July 2019]
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