Project Background
Mechanical Analysis
Mechanical analysis is a critical step analyzing the product design and material selection. It significantly impacts the entire mechanical system risk assessment
Topology Optimization
After mechanical risk assessment, the vey next question is how to mitigate/ manage risks and then what is more we can do to optimize the product design. Topology is a great approach reduce the excess safety margin and an effective way to balance quality and cost
Mechanical Analysis of Dining Chair
When designing a dining chair, one of the critical requirement is safely supporting an adult with average weight of 80 kg with a safety factor of 3-5. From CAD modeling, it beautifully demonstrated the artistic design of dining chair using surface features. Then the model is passed down to mechanical analysis to visualize the mechanical stress distribution and safety factor identification of safety factor. Originally the dining chair is designed with 2 mm thick steel, it satisfies the mechanical requirement, however, it’s very heavy and way over design. Therefore the cost will significantly increase. When cheaper plastic material is used as building material, of course compared to same dimension steel, it can sustain less force and also safety factor is below requirement. In optimization simulation, we identified if the plastic thickness is increased to 6 mm, then it’s not only meeting mechanical requirement but also reducing material cost.
Topology Optimization
A mechanical piece is used for bolting process. It satisfies mechanical requirement, but cost a lot of expensive metals. Our simulation approach helps client to identify minimal material requirement while keeping same mechanical support. By using topology optimization, we have achieved similar safety factor but with only 70% original material. This will be a very important in high volume manufacture to balance design requirement and cost reduction.