MECH 3460/8460/9460 - MECHANICAL SYSTEMS DESIGN 2
ASSIGNMENT 1 - Finite Element Design Analysis (FEA)
Part A - Bracket
























Figure 1 – Axle Support Bracket

This assignment requires you to use FEA, your knowledge of materials and manufacturing engineering plus
research to optimise and redesign two mechanical parts. You need to submit a written report (PDF format
ONLY! plus a ZIP file with all Solidworks files used) with figures and data to support your design (cite
sources as needed). MECH8460/9460 students have a larger page limit (see unit outline for page limits) and
are expected to provide a more detailed and higher quality submission.

NOTE: You must also submit a zip file (separate submission portal) with all
Solidworks files used in the creation of your report for parts A & B.

Failure to do so will result in a mark of ZERO for this task.

Assignment 1 contains two parts. Part A is an extension of the first Tutorial and requires that you first model
the Axle Support Bracket in Solidworks as described in the isometric view shown in Figure 1 and apply the
boundary conditions as defined below:

• If the last digit of your SID is even, apply a force of 3.5kN on the right face of the axle support
bracket as shown by the red arrow in Figure 1.0.

• If the last digit of your SID is odd, apply a force of 3.5kN on the left face of the axle support bracket
which is not shown, but acts in an opposite direction to the red arrow in Figure 1.0.

• If the last digit of your SID is even, apply a force of 2.5kN on the top face of the axle support bracket
as shown by the blue arrow in Figure 1.0.

• If the last digit of your SID is odd, apply a force of 2.5kN on the bottom face of the axle support
bracket which is not shown, but acts in an opposite direction to the blue arrow in Figure 1.0.

• If the second last digit of your SID is even, add a torque of 180 Nm to the inner bore of the axle
support bracket in an anticlockwise direction as shown by the green arrow in Figure 1.0.

• If the second last digit of your SID is odd, add a torque of 180 Nm to the inner bore of the axle
support bracket in the opposite direction to the green arrow as shown in Figure 1.0.

• In all of the above cases the bolt holes on the base of the axle support bracket must remain in the
positions as shown in Figure 1.0 (note there is also a non-visible third symmetrical bolt hole in the
base) and the relative position of the bore and bolt holes to each other must be maintained.


Use Solidworks Simulation (no other FEA package is permitted) to help you redesign the original Axle
Support Bracket to arrive at an optimised modified design that meets the following criteria:

a. Do not exceed 90% of the yield point of the material.

b. Reduce mass by at least 10%. A comparison of the mass of the original design vs your final mass
must be made in your report.

c. It is manufacturable by one of the methods noted in the Week 1 Tutorial (you must choose the method
of manufacture (3D metal printing is NOT permitted for this assignment).

d. It is manufactured from a suitable grade of aluminium that is compatible with the manufacturing
method selected in point c.

e. An Engineering Drawing (one sheet) to AS1100 (A3 sheet in pdf format) of your final optimised
design is also to be included as an attachment.

Note: An M8 x 1.25 threaded hole in line with the 9.0mm diameter hole should be included on the
lower face of the axle support bracket face as shown in Figure 2.0.














Figure 2 – Axle Support Bracket (Partial Cutaway View)


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