Design for Deflection

The objective of this project is was to learn how to apply analytical and numerical techniques to design an aluminum structure. The structure deflected linear elastically to a desired deflection under given applied load and boundary constraints. We first worked in pairs to model a C-shaped beam and used Castigliano's theorem and SolidWorks Simulation. Pairs were then grouped to form a team of 4, tasked with designing a structure that deflected .5" under a 200 lbf loading condition. The piece was cut and tested using an Instron testing device. 

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This was one the project in which I made the most mistakes, but as a result, is one in which I have learned the most. When modeling a structure, the class was asked to also take into account the weight. The more your part weighed, the more points were taken off. The first phase of the project had showed us the power of a C-shaped beam, but it was a heavy piece. I had begun playing with an angled L-shape and ran a simulation to test it out. After everyone else in the team had tested different shapes, we agreed on going in a different direction Aand moving away from the C-shape entirely. We had each calculated the deflection and gotten similar values. At this point, a family emergency occurred and I had to fly back home for a few weeks. With less time to machine the piece and heightened stress, we used the most recent structure we had designed, which had agreeing simulation values and calculations. The in-person results, however, were not at all in the ball-park. It had yielded!