Analysis for Designers

MM324
 When and How do I conduct an Analysis in the
Design process?
Identify Need

Specification Development

Correspond to Load Cycles

Concept Design & Selection
Concept Analysis / DFMA
Preliminary Design
Prelim Analysis
Detailed Design
Detailed Analysis
Manufacture

Distribute & Sell

 Concept Analysis
• Understand global reactions, major load cases/conditions for
Conceptual/Initial load cycle
• Hand calculations (FBD) and basic FEM
• Live loads, dead loads, handling loads, impact loads

• Usually concerned with Interfaces / Joints – Forces, Moments, Torques

• Bolt/fastener analysis, initial joint configurations
• Rough sizing of mechanical parts
• Parts are cartoons not yet fleshed out

• Basic material selection

• How can I apply DFMA to this concept?
• Manufacturing plan
 Concept Analysis – Cont’d
• What is your analysis plan?
• Identify critical analyses you need to conduct
• Create analysis templates – usually self contained in your excel file
• Major Joint sizing, bolt bending, shear etc, tension
• Fastener sizing (fastener diameters)
• Acreage sizing (gauge thickness)
• Stress Concentrations (feature design)
• Beam/column buckling (instability)
• Plate buckling (instability)
• Flange crippling (stress)
• Thermal mismatch (temperature effects)
• Natural frequency analysis (vibration/harmonics)
• Deflection analysis (is it stress of deflection dependent)
 Concept Analysis – Cont’d
• You want to understand kinematics (2D)
• How does your machine/mechanisms move
• Do I have enough range of motion, will it bind, will it break itself?

• Start to Reserve volumes in your design

• Always leave room for growth, don’t back yourself into a corner.
• How do parts/components fit together, create layouts
• If something were to change are you able to respond or are you over constrained.
 Concept Analysis – Cont’d
• Basic sizing of motors/actuators, power draw
• Concept/Initial Cycle Margin Policy is usually generous
• MS ≤ 30% depending on the programme/product goals
• Understand risks early

• Basic weight
• Cost estimate
• Must achieve a working baseline
• Trade studies are usually completed here

• Check against PDS/Requirements Compliance Matrix (RCM)

 Preliminary Analysis
• Select critical load cases – design driving LCs
• More detailed FEM for Preliminary loads cycle
• Natural Frequency FEM/Hand Calc
• Update concept analysis design file for prelim loads

• Joints and parts are defined

• hardware selected, bolts/fasteners, bushings, bearings, lugs
• Bolts patterns, weld designs
• Parts are 90% defined

• Kinematics are SOLID (3D is required)

• All potential interferences or risks are retired
 Preliminary Analysis – Cont’d
• Preliminary Cycle Margin Policy is usually tighter
• MS ≤ 10-20% depending on the programme/product goals
• Retire risks – design them out or size accordingly

• All trade studies closed

 Detailed Design
• Design loads cycle is completed
• Supported by test, wind tunnel data, CFD, instrumented rig/model

• Design Cycle Margin Policy is usually tightest

• MS ≤ 0-10% depending on the programme/product goals
• Higher the margin, higher the weight
• All risks carried are understood with mitigation plans in place

• Strength Check Notes (SCN) are written

• Design file completed as supporting document
• Sample analysis calculation in SCN one critical (minimum) margin of safety calculation
for each analysis conducted.
• Summary table for all critical checks completed at front of SCN.
• In each analysis check there should be a table of all margins for the entire assembly/part.