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Spring Design and FEA Analysis Guide

The document outlines a structured approach for designing a spring, including defining materials, dimensions, and loads, followed by design iterations involving calculations and simulations. It emphasizes the importance of CAD modeling, FEA simulations, and documentation, including detailed reporting and presentations. Additionally, it highlights the need for comparisons with standards and discussions on discrepancies and limitations.

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hassan lord
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2 views2 pages

Spring Design and FEA Analysis Guide

The document outlines a structured approach for designing a spring, including defining materials, dimensions, and loads, followed by design iterations involving calculations and simulations. It emphasizes the importance of CAD modeling, FEA simulations, and documentation, including detailed reporting and presentations. Additionally, it highlights the need for comparisons with standards and discussions on discrepancies and limitations.

Uploaded by

hassan lord
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

1.

Select an application (the tutor asked for this) and based on this
application:
1. Define the material
2. Define the main dimensions
3. Define the loads
2. Start the first design iteration including:
• Design assumptions and engineering standards used
• Final Geometry and material selection
• Load calculations (static/dynamic)
• Stress analysis calculations
• Factor of safety
• FEA calculations by hand (the tutor asked for this)
3. Make the CAD modeling and the FEA Simulation
1. Create detailed 3D CAD model of the spring (we can follow videos
from Dr. Mostafa Rashad on the spring modeling)
2. Applying material properties consistent with analytical work
3. Apply realistic boundary conditions and loads
4. Make a mesh sensitivity analysis (and plot the results)
5. Make a Fatigue analysis for the spring (after testing the K factor on
SolidWorks)
6. Extract results:
1. Stress distribution
1. von Mises
2. principal stresses
2. Displacement
3. Safety factor (if tool available)
4. Max and min values for all the above
4. Comparison & Discussion
1. We may compare our results to the standards if available
2. For the Discussion:
• Reasons for discrepancies
• Limitations of analytical assumptions
• Influence of boundary conditions and mesh
5. Make the Documentation (the report) including:
• Cover page
• Abstract,
• Introduction
• Methodology
• Application description
• Design process
• Calculations
• CAD modeling
• FEA simulation
• Discussion
• Conclusions
• References to design standards (very important)

1
• Make the appendix for (very important):
– Hand calculations
– standards excerpts
– mesh study
– simulation screenshots
6. Make the Presentation (based on the report)
7. Submit all the files including:
• It should include: Summary of work, key findings, Q&A
8. We should send all the CAD and FEA files as a drive link

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