MECH 3460/8460/9460 - MECHANICAL SYSTEMS DESIGN 2

ASSIGNMENT 1 - Finite Element Design Analysis (FEA)

Part B – Choose 1 of 2 options given

Part B of Assignment 1 allows you to explore FEA-focused design of ONE additional sample from a

collection of the two samples listed below.

Sample 1: Vertical Post

Figure 3 – Vertical Post (Not to Scale)

The vertical post shown in Figure 3.0 is made up of a low carbon mild steel 250mm Parallel Flange Channel

(PFC) 1500mm in length that is centrally located and welded to a horizontal base plate (500mm x 340mm x 25mm

thick) also manufactured from low carbon mild steel (you are free to select a grade that is suitable for your

design).

Your goal is to reinforce this connection by adding webs (wherever needed) and hold-down bolt holes (15mm in

diameter) at locations on the plate that are advantageous in minimising stress and distortion.

The base plate is to be held in place only by the bolt holes that you have defined in terms of their size and location.

Assume that the vertical post and base plate are welded together and that the joint require no specific analysis.

NOTE: You must also submit a zip file (separate submission portal) with all

Solidworks files used in the creation of your report for parts A & B.

Failure to do so will result in a mark of ZERO for this task.

Forces Acting on Vertical Post:

1. If the last digit of your SID is even, a force of 3.5kN is imposed in the direction of the blue and green

arrows on the black surface.

2. If the last digit of your SID is odd, a force of 3.5kN is imposed in the direction of the red and orange

arrows on the black surface.

3. If the second last digit of your SID is even, an additional force of 3kN is imposed in the direction of the

purple arrow on the black surface.

4. If the second last digit of your SID is odd, an additional force of 3kN is imposed in the direction of the

white arrow on the black surface.

5. If the third last digit of your SID is even, an additional torque of 100Nm is imposed in a clockwise direction

as shown by the brown arrow which acts on a perpendicular axis through the centroid of the beam.

6. If the third last digit of your SID is odd, an additional torque of 100Nm is imposed in an anticlockwise

direction to the brown arrow shown which acts on a perpendicular axis through the centroid of the beam.

The aim of this part of the Assignment is to arrive at a suitable modified design for the post assembly that best

meets all of the following criteria:

a. The Von Misses stress in any part of the post assembly must lie between 20% and 90% of the yield point

of the material.

b. The maximum amount of deflection of the post assembly in any direction must not exceed 2.5mm.

c. The weight of the of the post assembly must be reduced by at least 10% from its original weight.

Note: No Engineering Drawings are required for Sample 1 or 2 in Part B of this Assignment.

Sample 2: L Shaped Bracket

Figure 4

L – Shaped Bracket

Sample 2 is an L-shaped bracket (see Figure 4) that needs to be stiffened and reinforced to carry forces at

the holes shown. Four mounting holes are shown on the vertical side of the bracket to fix it to a rigid wall,

but you may choose a different number and locations for these holes.

You are required to modify the shape and thickness of this bracket such that with the loads indicated, its

deflection is reduced by a factor of 8. The modifications to the design of this bracket must be kept

practical, simple and light (mass may increase by no more than 40% of the original bracket).

You may add webs, welds, bosses, holes and alter plate thickness. The bracket is made from low carbon

steel (you are free to select a grade that is suitable for your design).

Forces Acting on bracket:

1.

If the last digit of your SID is even, a force of 950N is imposed in the direction of the blue and red

arrows.

2. If the last digit of your SID is odd, a force of 950N is imposed in the direction of the blue and green

arrows.

3. If the second last digit of your SID is even, a force of 850kN is imposed in the direction of the blue and

black arrows. Note: You must add the middle hole to the SolidWorks model supplied.

4. If the second last digit of your SID is odd, a force of 850kN is imposed in the direction of the purple and

black arrows. Note: You must add the middle hole to the SolidWorks model supplied.

Parts A and B of Assignment 1 Should Take an Average Student Approximately 15-20 hours to

Complete

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