The document summarizes several engineering design studies conducted through finite element analysis (FEA) software. Key findings include: 1) A study of a phone bezel and handset found the handset corner and top left bezel corner may fail under a 5 foot drop test due to exceeding the yield strength of the nylon material. 2) Analysis of rear phone bezel mounting clips found the original design would fail under 100 lbs of force but a redesign with increased wall thickness passed stress tests. 3) A toy wheel torque analysis found the original design was overengineered by 6 times the necessary strength; an optimized design with reduced plastic usage still passed strength tests.

1. LCD TV MOUNTING BRACKET STUDY
January 18, 2017
BY: Matthew Rossow

2. The purpose of this study was to evaluate the structural integrity of the engineered design and to
highlight any adverse effects of potential stress on the unit.
Preliminary studies indicated the mounting bracket can withstand the expected 70lbs threshold and
is over-engineered. FEA-Finite Element Analysis software was used to identify potential undesirable
feature characteristics through computer simulation. This document presents chronologically the
process of identification for part failure.
Material: Acrylic (Yield Threshold 45MPa)
ANALYSIS – A
TV MOUNTING BRACKETV on Mises stress Analysis
SUMMARY: No failure observed
ANALYSIS
70 Lbs. FORCE
RISK OF FAILURE

3. Purpose: The Factor of Safety test set to 2.0 resulted in no failure.
With this design during analysis we do not see any red (failure) elements. It appears to be a valid
design (see Fig.1)
ANALYSIS – B
TV MOUNTING BRACKET Factor of Safety Analysis
SUMMARY: No failure observed
ANALYSIS
70 Lbs. FORCE
RISK OF FAILURE

4. PHYSICAL DYNAMICS: CD SPRING CLIP STUDY
Physical dynamics was used to determine how the parts interact. Using this information, a spring
clip composed of Delrin 2700 plastic is subjected to 2lbs of force. The clip has yield strength of
63MPa. The blue band along the top of the clip indicates the part will not break.
ENLARGED VIEW

5. INJECTOR CAP STUDY
January 25th
, 2017
BY: MATTHEW ROSSOW

6. The purpose of this study was to evaluate the structural integrity of a redesign. The original
design for the injector breakaway nozzle was clogging the needle due to an excessive .020 inch
clearance between the injector breakaway head and the nozzle. Molds for the part had already
been produced at the cost of $30,000.
FEA-Finite Element Analysis software was used to identify undesirable feature characteristics
through computer simulation. This document presents chronologically the process of
identification, correction and optimization of engineered features.
Break Away Head Original Design
Material:Acrylic (Medical Grade Cast) (MPa Threshold 45 ≤)
ANALYSIS
BREAK-AWAY HEAD
RISK OF FAILURE .020 inch clearance

7. Break Away Head Redesign Solution
Material: Acrylic (Medical Grade Cast) (MPa Threshold 45 ≤)
My redesign added .010 inch inserts on top of the breakaway nozzle leaving clearance for fluid
to escape through the needle while preventing the breakaway from clogging the needle. Since
we are adding material, existing molds could be easily modified by drilling the inserts into the
mold.

8. ANALYSIS – A
INJECTOR NOZZLE BREAK-AWAY (FACTOR OF SAFETY (F.O.S.1))
JANUARY 25, 2017
The design displayed no failure in this analysis with the 10lbs total force. (see Fig.1)
5 LBs FORCE
RUPTURE
ANALYIS A

9. ANALYSIS – B
INJECTOR NOZZLE BREAK-AWAY (VON MISES STRESS ANALYSIS)
JANUARY 25, 2017
The results show the earliest controlled failure in red. The stress analysis indicates a successful
break away occurs with no indication of failure by the inserts. (see Fig.2)
BREAK AWAY

10. PAP DEVICE F.E.A. ANALYSIS
January 30th
, 2017
BY: MATTHEW ROSSOW

11. The purpose of this study was to evaluate the structural integrity of a pap device used to test for
cervical cancer. The needle was intended to inflate the balloon to collect a sample. The balloon
is then contained and sent to a lab.
The original design for the device could pop the balloon when more than 4lbs was applied and
posed risk of injuring patient since the needle was able to withstand too much force. A needle
that snapped near the tip posed additional risks.
A new design for the needle was needed so that the part would achieve controlled failure under
4lbs force, but stay intact under 3lbs or less.
FEA-Finite Element Analysis software was used to identify undesirable feature characteristics
through computer simulation. This document presents chronologically the process of
identification, correction and optimization of engineered features.
Original Design
NEEDLE

12. Redesign Solution
My design adds two parallel triangle cut extrudes spaced .95mm apart. The purpose for this design was
to avoid the symmetry of revolved cuts which would make the part stronger, make optimizing/iterating
the design efficient and keep the process of correcting the molds simple.

13. ANALYSIS – A
PAP DEVICE NEEDLE 4 LBS FORCE (FACTOR OF SAFETY (F.O.S. 2))
JANUARY 30, 2017
The design was able to achieve failure as indicated in red under 4lbs total force. Furthermore
there was no sign of failure at the tip of the needle. (see Fig.1)
RUPTURE

14. ANALYSIS – B
PAP DEVICE NEEDLE 3 LBS FORCE (FACTOR OF SAFETY (F.O.S. 2))
JANUARY 30, 2017
The design displayed no signs of failure under 3lbs force. Furthermore there was no sign of
failure at the tip of the needle. (see Fig.2)

15. ANALYSIS – C
PAP DEVICE NEEDLE (VON MISES STRESS ANALYSIS)
JANUARY 30, 2017
The yield strength is used to show the stress limit. The plastic Delrin 2700 needle shows
indications of failure at 4lbs force and is able to withstand 3lbs force.

16. ENLARGED VIEW
DROP TEST: CELLPHONE CASE STUDY
This case study was about learning to use the drop test simulation. The sample phone case was a dated
model that was not hollowed. Because it was a bulky solid, the case displayed no plastic deformation
from a 5 ft drop test and displayed only 12 thousandths of an inch displacement.
The purpose of this exercise was to introduce us to de-featuring which is important for suppressing
extraneous features to improve cpu calculation times as well as creating planes quickly/efficiently for
multiple points of impact.

17. PHONE BEZEL & HANDSET DROP TEST STUDY
February 6, 2017
BY: Matthew Rossow

18. The purpose of this study was to evaluate the structural integrity of a phone bezel and handset with a
drop test to see if the design is sufficient to keep the product from breaking when dropped from a
height of 5 feet. The phone is composed of Nylon 101 plastic (60 MPa) which is a cheaper, lower grade
of Nylon compared to Nylon 6/10 (139 MPa).
There are two assemblies (Handset and Phone Bezel) with a total of 4 areas that required advanced
analysis. FEA-Finite Element Analysis software was used to identify undesirable feature characteristics
through computer simulation.
Material: Nylon 101 (MPa Threshold 60 ≤)
*NOTE: The bottom right corner is identical to the top right corner and will post similar results. The four
handset corners are also symmetric. Duplicate tests were not required.
ANALYIS D*
SYMMETRIC
HANDSET CORNER
ANALYSIS A
BOTTOM LEFT
BEZEL CORNER
ANALYIS B
TOP LEFT
BEZEL CORNER
ANALYIS C
TOP RIGHT
BEZEL CORNER

19. ANALYSIS – A
BOTTOM LEFT BEZEL CORNER [NYLON 101] 5 ft. Drop Test
February 6th
, 2017
Results: The Phone Bezel lower left corner displays no signs of failure from the drop test. It is subjected
to 24.5 MPa (shown in red) near the apex of the corner which does not exceed the 60 MPa yield
threshold. Elastic behavior is observed and no engineering changes are required.
SUMMARY: PASS. NO SIGN OF PLASTIC DEFORMATION.
FLOOR
IMPACT

20. ENLARGED
ANALYSIS – B
TOP LEFT BEZEL CORNER [NYLON 101] 5ft. Drop Test
February 6th
, 2017
Results: The top left bezel corner displays possible signs of failure. It is the weakest of the bezel corners
and was subject to 62 MPa (shown in red) at the edges which is just above the yield threshold of 60
MPa. Engineering design changes are advised.
SUMMARY: FAIL. POSSIBLE FRACTURE OR PLASTIC DEFORMATION

21. ANALYSIS – C
TOP RIGHT BEZEL CORNER [NYLON 101] 5ft. Drop Test
February 6th
, 2017
Results: The top right and bottom right phone bezel corners display no signs of failure, but are close to
the yield of 60 MPa. The corner endures a force of 54.6 MPa.
It should be noted that the corner of the depression for the handset was subjected to up to 36 MPa. This
area should also be monitored if the phone were to be tested at greater heights.
SUMMARY: PASS. NO SIGN OF PLASTIC DEFORMATION.

22. ENLARGED
ANALYSIS – D
HANDSET [NYLON 101] 5ft. Drop Test
February 6th
, 2017
Results: The handset corner is subjected to 79 MPa on edges which exceeds the 60 MPa yield threshold
and would be subject to plastic deformation or fracture with the current design. Engineering design
changes are advised.
SUMMARY: FAIL. POSSIBLE FRACTURE OR PLASTIC DEFORMATION.

23. PHONE BEZEL MOUNTING CLIPS STUDY
February 13, 2017
BY: Matthew Rossow

24. The purpose of this study was to determine the structural integrity of the engineered design. The phone
design must endure 100 lbs of force from the top of the phone bezel. It is intended to be placed in or
near a bar where it is likely for someone to lean on it. FEA- Finite Element Analysis software was used to
determine the validity of the design.
Material: Acrylic (45MPa Threshold)
Original Design: The original design featured a .100 inch thickness which was set by the shell feature.
CLIP FIXTURE
ANALYSIS
100 Lbs. FORCE

25. ANALYSIS A
REAR PHONE BEZEL MOUNTING CLIP (FACTOR OF SAFETY (F.O.S. 3))
FEBRUARY 13, 2017
A factor of safety of 3.0 was chosen due to the customer requesting the phone to be designed with
safety requirements and a more sturdy design.
Results: FAIL. The design is insufficient to withstand 100lbs of force. The red areas indicate where the
phone is likely to fracture and plastically deform.

26. ANALYSIS B
REAR PHONE BEZEL MOUNTING CLIP (VON MISES STRESS ANALYSIS)
FEBRUARY 13, 2017
Results: FAIL. The phone is subjected to 64 MPa at the areas shown in red. This exceeds the 45 MPa
yield strength of the Acrylic and the design will fail under the force of 100lbs.

27. Redesign: An additional .400 inches were added to the back of the rear bezel. The purpose for this
redesign was to increase the wall thickness to a total .500 inches so the clips could withstand more force
while also not disturbing the layout of the internal components. Fixing the mold for the part will also be
a straightforward process of removing these inches from existing molds.

28. ANALYSIS C
REAR PHONE BEZEL MOUNTING CLIP REDESIGN (FACTOR OF SAFETY (F.O.S. 3))
FEBRUARY 13, 2017
Results: PASS. The mounting clips were able to withstand the 100lbs force. The red indicates that there
is likely to be buckling near the top of the bezel, but it did not extend across the length of the bezel. The
analysis displays no signs of failure of the mounting clips.

29. ANALYSIS D
REAR PHONE BEZEL MOUNTING CLIP REDESIGN (VON MISES STRESS ANALYSIS)
FEBRUARY 13, 2017
Results: The analysis displays that the rear bezel is subjected to 21 MPa which is well below the 45 MPa
threshold of Acrylic. Furthermore the simulation shows only 5 MPa on the clips. Elastic properties are
displayed and the phone is not likely to break under 100lbs force.

30. ANALYSIS E
REAR PHONE BEZEL MOUNTING CLIP REDESIGN (DISPLACEMENT)
FEBRUARY 13, 2017
Results: The displacement analysis displays .003 inches of displacement which is not significant
indicating the clips are not likely to deform.

31. FREQUENCY ANALYSIS
The purpose of this study was to determine the frequency of horizontal vibration and optimize the
design of a tuning fork to achieving the desired frequency. By changing the geometry and materials of a
model, the designer can avoid critical ranges to prevent failure or extend service life.
The tuning fork initially had a frequency of 440 Hz at a length of 4 inches and I was instructed to
redesign it to have a frequency of 400 Hz. This was achieved with the FEA software by shortening the
tuning fork to 3.792 inches.

32. THERMAL ANALYSIS
The purpose of this study was to analyze the heat transfer between a 7 Watt output central processing
unit and an aluminum alloy heat sink to determine if the heat sink design was adequate to keep the
processor within operating temperature.
A 7 Watt Heat Power is assigned to the face of the cpu and a fine mesh is created
Contact sets and convection entities are selected

33. THERMAL ANALYSIS CONTINUED
Results indicate the design of the heat sink would fry the processor at 219 degrees Farenheit
A larger heat sink is applied. The temperature under load stays within an operable 136 degrees Farenheit

34. COMPUTATIONAL FLUID DYNAMICS
The purpose of this study was to learn to use the flow simulation tools to simulate air passing around a
jet travelling at mach 2 to analyze pressure, temperature and laminar/turbulent flows with cut plots,
surface plots and flow trajectories.
Flow trajectory analysis to visualize airflow of a jet travelling at mach 2

35. COMPUTATIONAL FLUID DYNAMICS CONTINUED
Cut plot pressure analysis
Surface plot analysis of temperature showing which areas of the aircraft generate the most heat from friction

36. TOY WHEEL TORQUE ANALYSIS
March 04, 2017
BY: Matthew Rossow

37. Purpose: The purpose of this study is to evaluate the structural integrity of an engineered design and
determine the elements of potential failure under a torque test with 30 lbs of force.
FEA-Finite Element Analysis software was used to identify undesirable feature characteristics through
computer simulation. This document presents chronologically the process of identification, correction,
and optimization of engineered features.
Material: Acrylic (MPa Threshold 45MPa)

38. ANALYSIS – A
PLASTIC TOY WHEEL TORQUE ANALYSIS (ORIGINAL DESIGN)
March 04, 2017
Results: The plastic toy wheel appears to be over-engineered. During analysis I found that the wheel
was 6x stronger than the material yield of 45 MPa under 30 lbf torque showing stress of only 7.5 MPa at
the joints. The outside wheel displays less than 2 MPa leading me to believe the internal ribs on the
underside of the wheel are unnecessary.
Summary: PASS. NOTE: OVER-ENGINEERED BY A FACTOR OF 6x AT THE JOINTS
JOINTS UNDER
HIGHEST STRESS

39. ANALYSIS – B
PLASTIC TOY WHEEL TORQUE ANALYSIS (REVISED/OPTIMIZED DESIGN)
March 04, 2017
Results: After reduction in wall thickness from .100 inches to .050 inches and complete removal of all
internal ribs, the part still displays elastic behavior. The joints are subjected to 25 MPa which is still well
below the 45 MPa yield strength.
The test indicates the part is still over engineered, but reducing thickness below .050 inches is not
advised due to the mold process.
Summary: PASS

40. ANALYSIS – C
STEERING WHEEL DISPLACEMENTANALYSIS (REVISED/OPTIMIZED DESIGN)
March 04, 2017
Results: The wheel shows displacement of only .091 which is acceptable and is not likely to compromise
functionality.
Summary: PASS

41. MATERIAL COST ANALYSIS
ORIGINAL OPTIMIZED
SUMMARY: I reduced the overall plastic used per part and generated savings of 55% with the new
design without sacrificing the stability or safety of the part under 30lbf torque.
Original weight .20 lbs. Optimized weight .09 lbs.