EG 264 CAE Solidworks Assignment 2023/24

EG-264 – C2 - Solidworks Coursework (50%) 2023/24

Turnitin Submission Deadline: 4pm Friday 15th December 2023

Solidworks Assignment – Loaded Bracket Design Optimisation

Background
A bracket made from 1023 Carbon Steel Sheet (SS), able to withstand between 700 N to 1000
N acting on the last 10mm top surface needs to be produced. The selected design cannot fail in
service, so a design of experiments (DOE) approach is to be adopted to optimise to a final
product.

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.

(N.B. Although the CAD drawing in Figure 3 shows the variables used in its design, the drawing
has not been created to the initial model dimensions provided, in Table 1).

Table 1: Initial Bracket variables and dimensions

V1 Top Length 95mm

V2 Plate Thickness 6mm

V3 Bracket Width 45mm

V4 Brace Plate Height 25mm

V5 Brace Plate Angle 45deg

V6 Hole Diameter 5mm

V7 Brace Plate Fillet 3mm

V8 Bracket Corner Fillet 4mm

V9 Hole Height Offset (from bottom of corner fillet) 10mm

The bracket is to be bolted to a face plate, so the holes are required to accommodate bolts
between M3-M6 size. The face force load at the end of the bracket’s top surface (acting across
the width) of the last 10 mm is predicted to be between 700 N and 1000 N (Figure 2). There are
two separate fillets in the design, the largest being the bracket corner fillet (V8), and there is also
a fillet surrounding the mid plate (V7) as shown in Figures 1 and 3.
EG 264 CAE Solidworks Assignment 2023/24

The final part design choice must evidence, using FEA simulation, meaningful information in
terms of low cost, low weight and high strength. The designer must consider manufacturability,
sustainability while using an appropriate safety factor. To help deliver this, the designer is able
to 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 simulation should consider two levels (high and low) for each of the altered
control factors.

Additional design requirements to consider:

The designer should also consider the effects of the design under temperature, where an increase
in temperature (from ambient) of 40 ̊C is predicted. It has also been suggested that when fitting
the optimised bracket to the face plate it must be fitted with a fool proof (poke yoke) feature, and
that the bracket must be precisely aligned.

Design of experiments
The Taguchi design of experiments (DOE) method is to 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. The sixteen experiments 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.
EG 264 CAE Solidworks Assignment 2023/24

Table 2: Taguchi L16 Orthogonal Array Design example

RUN 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
EG 264 CAE Solidworks Assignment 2023/24

Description of Task
As part of your design, you will need to undertake the following tasks:

• Create a study
• Assign material properties
• Define loads and restraints
• Mesh the model
• Run the model
• Find minimum and maximum stress, strain and deformation based on face loading.
• Plot and compare the stresses at the mid plane of the data acquisition surfaces.
• What is the safety factor of the model?

Steps to take:
Once the CAD is complete, set up the study following these steps first (lecture notes)

• Start SOLIDWORKS Simulation

• Familiarise yourself with the:
o SOLIDWORKS Simulation Interface
o Command Manager
o Options window.
o Plot Settings
• Pre processing
o Assigning Material Properties
o Create a study.
o Set fixtures
o Set loads (see Fig: 2)
o Mesh
o Run
• Post processing
o Using Plot tools- review
▪ Stresses
▪ Strains
▪ Deformation
▪ Factor of Safety
In the report
• Demonstration of mesh refinement and control (ideally before the final 16
experiments).
• The description of the optimum design for Low cost, low weight and high strength
product (all claims must be backed up with evidence).
• A plot of the maximum von Mises stress results for all simulations.
• A plot of the minimum factor of safety for all simulations.
• A plot of the displacement results along one side edge on the top surface for all
simulations.
• Consideration of additional design requirements.
EG 264 CAE Solidworks Assignment 2023/24

Assessment
The assessment for this task will be based on an individual report (6 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 the EG264 module. The following criteria will be used to
assess the reports:

1. Introduction to the overall design task (10 %).

2. Description of the key features of your design and the rationale for the design choices
that have been made (20 %).
3. Completion of the simulation experiments with results summary (20 %).
4. General arrangement drawing of optimised design (10 %).
5. Conclusion (20 %).
6. Overall quality of report (20 %).

Timelines
The project will start on Friday 24th November 2023 and the deadline for the submission of the
report is 4pm on Friday 15th December 2023.
EG 264 CAE Solidworks Assignment 2023/24

Resources
https://www.solidworks.com/sw/resources.htm

Figure 1: Basic bracket design

Figure 2: Face Load Distance

EG-264 CAE Solidworks Assignment 2023/24

Figure 3: Bracket Layout Drawing

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