EG-264 CAE C2 - SOLIDWORKS Assignment 2021/2022
EG-264 – C2 - SOLIDWORKS Coursework (50%) 2021/22
Turnitin Submission Deadline: 4pm Wednesday 8th December 2021

Assignment – Industrial Loaded Bracket Design Optimisation

The assessment for this task will be based on an individual’s report (5 PAGES
MAX INCLUDING the Part Drawing (drawing must be A3 in size) - NO
appendices, cover page does not count towards page total. Any pages after
reaching the page limit will not be marked. This assessment contributes 50% to
the final grade of EG-264.

The following criteria will be used to assess the reports:

1. Introduction to the overall design task (10 %).
2. Description of the key variables of your design and the reasoning for the
design choices that have been made (20 %). (Specifically, why you altered
the variables chosen, and how they affect the improved design compared to
the initial values and those not altered).
3. Completion of the simulation experiments with results summary (20 %).
4. Technical drawing of optimised design (10 %). – (N.B If the part cannot be
manufactured from the drawing, the max mark for this section will be 4%).
5. Conclusion (20 %).
6. Overall quality of report (20 %).


Basic Details:
For this INDIVIDUAL assignment, a technical report detailing your solution for the
optimisation of the design is required. This should be submitted as a single PDF
document and submitted through the Turnitin link on Canvas.

In the report you should consider (but are not limited to)
• The analysis of the optimum design for a low cost, low weight and high
strength product, but it is NOT to be over/under Engineered (all claims must
be backed up with evidence).
• Demonstration of mesh refinement (before the final 16 simulations).
• A plot of the von Mises stress results ALONG one edge of the shelf length for
all simulations (See Figure 2).
• A plot of the bracket’s factor of safety for all simulations.
• A plot of the displacement results ALONG the edge of the shelf length for all
simulations (See Figure 2).
• Consideration of additional design requirements - What temperature can
the final optimised bracket design be used in?
• A comparison of the initial to optimised bracket design shown in Figure 3.



EG-264 CAE C2 - SOLIDWORKS Assignment 2021/2022

Background:
An industrial bracket manufactured from Alloy Steel is used in an industrial
environment used in conjunction with other similar brackets, each fixed to a plate
on a wall. A shelf lays on the horizontal surface and is attached using three vertical
bolt holes (6mm diameter). The mass applied to each individual bracket (acting
vertically down) is 110kg ±10%. The brackets are supporting the shelves in a
working warehouse, in which there is no air conditioning for the workforce, and so
the temperature varies throughout the year. The temperature can reach a high
point of 40 degrees Celsius.

The selected design cannot fail in service, so a design of experiments (DOE)
approach is to be adopted to optimise to a final suitable product. The bracket is to
be made as light as possible and MUST NOT be considered under or over
engineered.

An initial design structure has been generated, and there are several variables that
are used to create the initial bracket design as shown in Figure 3, with numerical
values stated in Table 1.

Table 1: Initial Bracket variables and dimensions

V1 Height 140 mm
V2 Brace Angle 30 deg
V3 Length 200 mm
V4 Brace Width 10 mm
V5 Width 40 mm
V6 Bolt Holes Diameter 6 mm
V7 Thickness 3 mm
V8 Hole Height 40 mm

The bracket is to be fixed in place through the three holes through the back plate of
the bracket. The force loading imposed on the bracket is in the normal direction to
the top surface of the bracket shelf (Figure 2). The area to which the force is applied
on the bracket, is the full width and, the whole top surface to the vertical face (see
Figure 2). For this assignment, a structural analysis of the initial bracket must be
done, and if the initial bracket is unsuitable for the requirements, a suitable
optimised bracket design is to be generated.

Considering that the assignment part is an industrial shelf component, where
workers will be situated, and that there is a possibility that the working
temperature could increase from normal ambient temperatures. This may need
consideration during the design process.

The final part design choice must evidence, using FEA simulation, meaningful
information in terms of being low cost, low weight and of suitable strength. The
designer must consider manufacturability and sustainability while using an
appropriate safety factor to not be under or over engineered. To help deliver this,
EG-264 CAE C2 - SOLIDWORKS Assignment 2021/2022
the designer can vary any FOUR of the control factors (bracket variables), while
keeping the remaining variable dimensions as those shown in Table 1.

N.B – You will need to explain your reasoning for your choice of variable changes.
For optimisation, the variables chosen to be changed in the simulations should
consider two levels (high and low) for each of the altered control factors.

Design of experiments
The Taguchi design of experiments (DOE) method can be used to plan the
simulations (table 2). The DOE objectives are to acquire data in a controlled way,
obtaining information about the behaviour of the bracket and to also identify
significant factors affecting the design when it experiences a force. With 4 control
factors being changed, sixteen experiments will simulate and will be used to
identify a low cost, low weight and high strength design by investigating the von
Mises stress, displacement and factors of safety responses.

Table 2: Taguchi L16 Orthogonal Array Design example

RUN Control Factors
1 2 3 4
1 1 1 1 1
2 1 1 1 2
3 1 1 2 1
4 1 1 2 2
5 1 2 1 1
6 1 2 1 2
7 1 2 2 1
8 1 2 2 2
9 2 1 1 1
10 2 1 1 2
11 2 1 2 1
12 2 1 2 2
13 2 2 1 1
14 2 2 1 2
15 2 2 2 1
16 2 2 2 2

Description of Task
As part of your procedure, you will need to undertake the following tasks to the
design provided:
• Create a 3D model based on assignment drawings.
• Create a simulation study
• Define loads and constraints
• Mesh the model (using curvature based mesh)
• Run the model and perform a mesh dependency study to ensure correct
results.
EG-264 CAE C2 - SOLIDWORKS Assignment 2021/2022
• Paramaterise the design variables coefficients.
• Perform a design study varying FOUR of the model coefficients with a low
and a high value to obtain the 16 simulation run results.
• Find the Von Mises stresses and resultant deformations.
• Plot and compare the stresses and resultant displacements along the edge
of the shelf length of the bracket for each scenario generated, along with the
determined factors of safety.
• Is the factor of safety of the model suitable? Under or over engineered?
• What temperature increase can the bracket endure?


Assessment MARKING structure:
The assessment for this task will be based on an individual’s report (5 PAGES
MAX INCLUDING the Part Drawing - NO appendices). Marks WILL BE LOST if
the report submitted is longer than the maximum page limit. The mark that is
achieved will contribute 50% towards your final mark for EG-264.

The following criteria will be used to assess the reports:

1. Introduction to the overall design task (10 %).
2. Description of the key variables of your design and the reasoning for the
design choices that have been made (20 %). (Specifically, why you altered
the variables chosen, and how they affect the improved design compared to
the initial values and those not altered).
3. Completion of the simulation experiments with results summary (20 %).
4. Technical drawing of optimised design (A3) (10 %). – (N.B If the part cannot
be manufactured from the drawing, the max mark for this section will be
4%).
5. Conclusion (20 %).
6. Overall quality of report (20 %).

This should be submitted as a single PDF document and submitted through the
Turnitin link on Canvas.

Timelines
The project will start from week commencing 8th November 2021 and all
submissions MUST be in BEFORE 4pm on Wednesday 8th December 2021,
submitting via the Canvas Turnitin link.


Work that is submitted late will be awarded zero marks.

Late submission due to certificated illness or extenuating circumstances will be
dealt with according to standard procedures.

Email: a.c.tappenden@swansea.ac.uk

EG-264 CAE C2 - SOLIDWORKS Assignment 2021/2022










Figure 1: Basic bracket design



Figure 2: Loading and Probe location
EG-264 CAE C2 - SOLIDWORKS Assignment 2021/2022


Figure 3: Bracket Layout Drawing (Not a Technical Drawing)