The challenge: A client approached ESR with issues of cracking of a mounting bracket, supporting a component subject to complex loads.
Our solution: Based on the geometry supplied by the client and measurements taken from components we sectioned in the lab, we created a de-featured model of the bracket and modelled the adjacent components to ensure realistic boundary conditions. We applied a range of worst-case loads to the part to determine the regions of highest stress concentrations, and the sensitivity to different loads.
Based on our model, we were able to recommend design changes, as well as an improved set of design loads for future iteration.
