1023 Carbon Steel

INTRODUCTIONThe objective of the project was to optimize a bracket made of 1023 Sheet (SS) towithstand a load of 700N-1000N while keeping the cost and weight down and the strength high.The bracket will be bolted to a face plate and the force is acting at the end of the top surface of theplate along the width on patch of 10mm material along the length. The boundary conditions forthe analysis is shown below in Fig. 1.Fig. 1 Boundary Conditions on BracketThe bracket was optimized with the help of Finite Element Analysis using Solidworks 2016.There were 16 variations of the bracket which were done using Taguchi design of experiments(DOE) by changing 4 variables in the bracket and keeping rest the same.Results were judged on the basis of Von-Mises Stress, Equivalent Stress, Factor of Safety,Deformation and Weight.KEY FEATURES AND DESIGN CHOICESThe bracket needs to withstand a load of 700-1000N, so for the analysis the maximum load of1000N was applied on the model. Mesh control was applied on the simulation, the mesh size atthe fillets and holes were decreased to increase the accuracy of the simulation and provide a moreuniform mesh. Mesh element size of 1.5mm was chosen and a/b ratio of 1 was chosen. Only V11,V12, V15 and V16 were able to withstand the load, the rest of the variations of the design faileddue to the value of factor of safety being less than 1. V16 was chosen as the final model to bemanufactured due to the weight being 2 grams more than V12 (lightest variation that passed) andit having the maximum factor of safety. To reduce the stress concentration, chances of warpageand manufacturing defects, the following changes were made to V16 (Fig. 2):1. Added a fillet of 4mm on the corners of the bracket to avoid injuries due to sharpedges and decrease stress concentration2. Added a fillet of 8mm on the perpendicular edge of the bracket to reduce stressconcentration.Fig.2 Comparison Between V16 And Final Model for ManufacturingCOMPARISON BETWEEN VARIATIONSTo compare the different variations of the bracket made according to Taguchi design ofexperiments (DOE), the variables that were changed are as follows:1. Plate Thickness (V2) – It is one of the contributing factor to strength and weight ofthe bracket2. Brace Plate Angle (V5) – With change in the angle of the brace plate, the support atthe top face of the bracket where force is applied changes3. Brace Plate Height (V4) – With change in height of the brace plate, the stress on thevertical face of the bracket changes because the area of contact changes on thevertical face4. Hole Diameter (V6) – With change in hole diameter, the weight as well as the stressaround the holes changesThe above four parameters were chosen for optimizing the design because these four parameterseffect different parts of the bracket and when combined together, these four parameters control thebehaviour of the bracket as a whole.The following table was designed to show the various parameters that were altered to perform theanalysis:

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