This was a supplementary project to a mechanical design class. We had to create a design for a system with at least 1 automated component and perform all calculations/analysis on the system for static/buckling/fatigue/power transmission failure. I created a springboard with an automatically adjustable fulcrum, meaning the fulcrum would change position without being manually turned.
During 6 weeks, our group built a full CAD model, performed all calculations, and 3D printed a prototype. We composed 5 technical reports, each being 20+ pages. These reports summarized all calculations, FEA analysis done in SolidWorks, and all discussion questions from the class. Below are a few of the FEA simulations that I helped run.
Static FEA Analysis of the System
FEA shows the stress concentrations for the springboard were concentrated in the middle.
Loading conditions were placed on the handlebars to show how stress would propogate from a constant load.
Buckling FEA Analysis of the System
Constant load for worst-case scenario was placed in FEA software to show how the column would buckle.
Buckling in the handlebars was created from simulating the load and how the handlebars deform.
This project allowed me to learn how to design a system to function with infinite life, ensuring that it would not break due to any loading conditions. It allowed me to build skills in design, FEA simulations, design-based calculations, and technical writing.