Mounting Bracket Design - Topology Optimization & FEA Validation
Michael Marcos
Challenge: Lightweighting a Mounting bracket for Material Efficiency
Mounting brackets are ubiquitous engineering components. However, over-designed brackets use excessive material, increasing weight and cost. This project addressed the challenge of reducing material usage and weight in a mounting bracket while maintaining its structural integrity under load, utilizing the powerful technique of Topology Optimization.
Solution: Topology Optimization and FEA Validation in SolidWorks Simulation
To achieve a lightweight yet robust design, I employed a two-pronged approach using SolidWorks Simulation:
Topology Optimization Study: I utilized SolidWorks Simulation's Topology Study tool to intelligently remove material from non-critical areas of the initial bracket design. This was achieved by defining:
• Load and fixture conditions representative of the bracket's intended application.
• Design space – the initial volume from which material could be removed.
• Optimization goal – to minimize mass while maintaining a target factor of safety or maximum stress limit.
• Manufacturing constraints (symmetry, preserved regions)
Finite Element Analysis (FEA) Validation: After obtaining the topology optimized shape, I performed a detailed Static Stress Analysis in SolidWorks Simulation on both the original bracket design and the topology optimized design. This FEA validation served to:
• Verify the structural integrity of both designs under the applied load.
• Compare stress distribution and deformation between the original and optimized brackets.
• Confirm that the topology optimized bracket achieved significant weight reduction without compromising structural performance.
Key Deliverables & Visualizations:
This project delivered a clear visual story of design optimization and structural validation through a series of images showcasing different stages of the process:
Image 1: Topology Study Results - Optimized Bracket Shape
Description: An image showcasing the result of the Topology Study. This visualization clearly displays the optimized shape of the mounting bracket after material removal, highlighting the areas where SolidWorks Simulation intelligently removed material to achieve lightweighting.
Topology Study Results
Topology Study Results
Image 2: Original Bracket Design - Before Topology Optimization
Description: An image of the original mounting bracket design, before the Topology Optimization study was applied. This provides a direct visual comparison to the optimized design, clearly demonstrating the material reduction achieved through topology optimization.
Unoptimized Bracket
Image 3: Stress Analysis - Optimized Bracket (Von Mises Stress)
Description: A contour plot visualizing the Von Mises stress distribution on the Topology Optimized Mounting Bracket under load. This image demonstrates the stress levels in the lightweight design, confirming its structural integrity and identifying areas of stress concentration.
Skills Utilized:
✅ Topology Optimization
✅ Finite Element Analysis (FEA)
✅ SolidWorks Simulation (Topology Study & Static Analysis)
✅ Structural Mechanics Principles
✅ Design for Lightweighting
✅ Material Efficiency
✅ Engineering Analysis
✅ Data Visualization & Interpretation
Tools Used:
Software: SolidWorks Simulation (Topology Study, Static Analysis, Motion Simulation), SolidWorks (CAD Modeling)
Why This Project Matters:
This Lightweight Mounting Bracket project effectively demonstrates my proficiency in:
• Applying Topology Optimization to achieve significant material and weight reduction in mechanical designs.
• Utilizing SolidWorks Simulation for both Topology Optimization and rigorous Finite Element Analysis validation.
• Visually communicating the benefits of topology optimization and structural performance through clear and compelling visualizations.
• Demonstrating a holistic approach to design – from initial concept to optimized and validated solution.
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Posted Feb 18, 2025
Topology Optimization for Lightweight Bracket Design. Project used SolidWorks Simulation to reduce material in a mounting bracket while ensuring structural inte
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