FEA Simulation & Structural Optimization for Industrial Mounting Assemblies

Objectives

What the project needed to achieve

• Build an FEA model for defined static load cases up to 8.5 kN
• Perform mesh sensitivity studies to ensure stress singularity independence near constraint edges
• Identify high-stress zones exceeding target allowable stress thresholds
• Iterate gusset and fillet geometry to reduce peak von Mises stress by over 25%
• Maintain a structural factor of safety exceeding 2.0 against material yield

Challenge

Engineering constraint

The industrial mounting bracket study focused on stress concentrations near transition corners and bolt holes under defined static load cases. Increasing member thickness uniformly can add material; the study compared localized rib placement and fillet-radius changes as geometry alternatives.

Approach

How YantriX approached the work

1. 01

   Imported parametric bracket solid geometry into ANSYS and SolidWorks Simulation environments.

2. 02

   Conducted baseline FEA on original geometry, revealing high localized stress (285 MPa) near base bend radii.

3. 03

   Refined mesh density locally using adaptive h-refinement at notch radii until stress converged within 3%.

4. 04

   Introduced continuous triangular stiffening gussets and increased inner bend radii from 2 mm to 5 mm.

5. 05

   Re-ran static stress and displacement solvers across baseline and optimized design variants for direct comparison.