Finite Element Analysis
Finite Element Analysis (FEA) is a powerful tool used to simulate how objects behave under various conditions, such as pressure, temperature, compression, and tension. By conducting these simulations virtually, engineers can save significant time, resources, and energy compared to physical testing. This process is invaluable for predicting performance, identifying potential failures, and optimising designs before moving to real-world testing. FEA also provides valuable insights into material properties and behaviour, enabling engineers to make informed decisions during the design process.
Mesh Sensitivity Analysis in FEA: Stress and Strain Behavior of Aluminium Rods under Compression and Tension
The images below showcase the effects of varying mesh sizes on an aluminium rod subjected to different conditions, such as compression and tension. Using Fusion 360, I performed multiple Finite Element Analysis (FEA) simulations to gather data on key characteristics, including stress, strain, displacement, and safety factors. This data was compiled into a table, which was then used to create stress-strain and shear stress-shear strain graphs for both compression and tension scenarios, providing a detailed analysis of the material's behaviour under these conditions.
Thermal Management in Rod Design: Impact of Surface Area and Material Properties
In this analysis, I explored the effect of varying surface area and material properties on heat dissipation in a rod subjected to a fixed heat source. The front surface of the rod was kept at 50°C, and different configurations were tested to observe the temperature distribution along the length of the rod. By increasing the surface area through the addition of features such as fins, the heat was able to dissipate more effectively into the surrounding environment, resulting in a lower temperature at the far end of the rod compared to the baseline scenario (with no added surfaces).
In addition to surface modifications, I also investigated the impact of different materials, with the goal of reducing both weight and cost while maintaining efficient thermal performance. The results showed that material choice and geometry play a significant role in heat transfer and the overall thermal management of the system.
Optimisation and Safety Analysis: Load Behaviour and Generative Design in Fusion 360
The image above illustrates the behaviour of a hook under a 1000N applied load. The simulation shows slight deformation, but the hook remains safe for use, with a safety factor of 3.43, which exceeds the minimum required safety factor of 3. To further optimise the design, I tested the hook with alternative materials, aiming to reduce both cost and weight while maintaining an acceptable safety factor.
Generative design in Fusion 360 enables the software to propose optimised geometries that enhance the effectiveness of a design. By leveraging computational algorithms, the tool suggests potential shapes and structures based on various parameters such as weight, safety, and minimal displacement. These suggestions allow you to select the best design that meets your specific priorities and performance requirements.