Introduction
A compliance link is to be designed to give the maximum axial movement between 0.2 and 1.2 mm, The weight is to be maintained at minimum, under a load of 450N, with a safety factor of 2, without the material yielding. The load is to be applied by two 11mm diameter pins in two 12 mm diameter holes. There must be two 8 mm diameter assembly holes in the specified area of the part, but other holes can also be allocated to reduce the weight.
The pre-drilled blank to be used is shown in the following diagram.
Assignment Details
Part A
Design a link to fulfill the design requirements incorporating the pre-drilled holes. The minimum radius required around the two 11.1 diameter holes for manufacture is 10mm radius.
Part B
Optimise the link design to minimise the weight, without compromising safety.
Part C
Use CNC simulation to prepare a suitable CNC program and machine your new design on the machining centre. The cutters available 8, 10 and 15 diameter the station numbers and other data will be given when available. Carry out a test on a material test machine to confirm satisfactory operation with the load plus safety factor. Note the test conditions and results and use them to confirm your FE model.
Part D
Note the test conditions and results and use them to confirm your FE model. Compare with at least one other validation method.
Part E
Submit for assessment a list of the files on the system and a report explaining the work undertaken, the results obtained and your comments and conclusions. You should include details of the FE analyses carried out (such as alternative boundary conditions) and explanations of the rationale employed.
Material data
Aluminium alloy with E = 70 GPa and Yield stress of 124 MPa