Bracket Optimization, simulation used to influence part geometry.
Goal: Use simulation to redesign the given part to decrease weight, while still meeting loading requirements.
Weight: 4.52lb
Unmodified Yield FoS = 2.5
Unmodified Max Deformation = .0014in
New Weight: 3.00lb (33.6% reduction)
New Yield FoS = 2.4
New Max Deformation = .0019in
Motorcycle Brake Lever, simulation used to ensure the part will not yield under load.
Goal: Use simulation to estimate peak stress under emergency braking input scenario.
Conclusion: Lever will not fail under 200N braking force
Mesh element size = .002m
Yield FoS = 5.4
0.6mm Max Deformation
Motorcycle connecting rod, simulation used to learn about design choices.
Goal: Use simulation to explore how stress distributes through the I-beam cross section of the shank, and understand why connecting rods are shaped the way they are.
Insight gained: The I-Beam design of a connecting rod is a key feature of it’s design. My redesigned rod with the same mass showed much higher stresses, meaning the shape of a connecting rod has a significant impact on it’s strength.
Motorcycle Connecting Rod
My Redesign
I-Beam Max Stress = 399 MPa
Hollow Rectangle Max Stress = 543 MPa