Design Optimization initial part to the optimized design. For this calculation assume the density of steel = 0.282 Ib/in’ and that 2,500 parts are made per year. g Questions: (1) Which Constraint appears to be the “limiting factor” for this design optimization and what result(s) lead you to this conclusion? (2) If Min: and Max: Range values were changed again, might a better solution be found! Give sound reasons for your answer by referring to values listed in the Optimal solution. EXERCISE 2 - Design Optimization of Slotted Rectangular Block The initial design of a slotted rectangular block, used to measure lateral (sideways) loads on an outdoor structure, is shown in Fig. E8-4. In its final configuration, not shown, strain gages are to be mounted on its left and right vertical legs to measure bending stress and correlate those stresses to loads applied to the structure. When in service, the part is fixed on its bottom surface and subject to a maximum horizontal force of 200 Ib applied to its upper left edge as illustrated in Fig. E8-4 (a). To obtain larger strain magnitudes at the gage locations, if it is desired, reduce the width and thickness (depth into the page) of both vertical legs. ‘The approach proposed is to minimize volume of the slotted block by reducing the width of the two vertical legs and thickness of the block. Common sense dictates that doing so will result in larger deflections with resulting higher strains measured by the strain gages. Practical limitations, however, restrict displacements to 0.05 inch or less and limit stress in the part to 32,000 psi or less. Open file: Slotted Rectangular Block 8-2. (a) (b) Figure E8-4 ~ Loading and geometry of the Slotted Rectangular Block. © Material: AISI 1020 steel 8.29Analysis of Machine Elements Using SOLIDWORKS Simulation © Mesh: System default Curvature based mesh. © Fixtures: Fixed (immovable) restraints applied to bottom surface. * External Load: Apply a 200 Ib horizontal force to the top left edge of the model. ‘* Limitations: Maximum von Mises stress < 32000 psi. Maximum part deflection < 0.05 in. Determine the following: Develop a finite element analysis that includes material specification, fixtures, extemal Joad(s), mesh, and initial and optimized solutions. a, Run an Jnitial Study for the original part to form the basis for an Optimization Design Study which is to follow. Create a plot showing the restraints and external loads applied to the model along with the initial von Mises stress distribution, IMPORTANT: SAVE the results of this initial analysis for possible re-use. b. Based on the Initial Study, create a new Optimization Design Study that results in reduction of the width of the two vertical legs and thickness of the entire part. Dimension changes are limited to the dimensions labeled in Fig. E8-5. See step (c) for items to be done prior to running the optimization study. These are the initial dimensions: © Left vertical leg initial width = 1.75 in © Right vertical leg initial width = 1.75 in ‘* Thickness (depth into the page) = 2.00 in Figure E8-5 ~ Dimensions that are to be reduced on the slotted rectangular block. 8-30