Electronic assembly structural analysis
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This document summarizes structural analysis of an electronics assembly using Solidworks FEA simulation. It analyzed the assembly under random vibration, shock, and inertial acceleration load cases. The analysis found that the maximum stresses occurred under combined acceleration loading but were still below the yield strength of the 6061-T4 aluminum material. Shock load stresses were insignificant. The assembly's main mounting bolts require a yield strength of at least 100,000 psi. The analysis concluded the assembly design is structurally adequate for the specified environments.
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Detailed design calculations & analysis of go kart vehicle
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Electronic assembly structural analysis
- 1. Structural Analysis Solidworks FEA Simulation Advanced Dynamics Date: Jan 14, 2015 D. Blanchet 1 Reference image Typical electronics Assembly Lockheed Martin CEEU
- 2. • Total Assembly weight = 152 lbs • Material 6061-T4 Dip Brazed Aluminum – Yield strength = 21,000 psi – Ultimate strength = 35,000 psi • Load Cases – Random Vibration – Shock – Inertial Acceleration • Nominal part dimensions are used in the analysis Assumptions – custom assembly concept 2
- 3. Simplified SW model Electronics Assembly 3
- 4. Solidworks FEA meshed model (900,000 D.O.F.) 4
- 5. Solidworks meshed model covers removed 5 Backplane
- 6. Solidworks FEA Detailed fine mesh 6 High Stress Zone At Mounting Foot Braze Joint
- 7. Random Vibration test level D 8.92 Grms 7 Applied individually to 3 axes.
- 8. Random Vibration Results – stress side to side 8 3 sigma Von Mises Stress = 4,500 psi
- 9. Random Vibration Results – displacement side to side 9 3 sigma Displacement .012 inches
- 10. Random Vibration Results - Summary 10 Direction input PSD 3 sigma Displacement 3 sigma Stress psi Factor Of Safety* Side-to-side 8.92 Grms .012 (plenum) 4,500 (foot) 4.6 Up - down 8.92 Grms .014 (plenum) 6,000 (foot) 3.6 Front-to-back 8.92 Grms .012 (IO cage cover) 3,900 (foot) 5.4 * Factor of safety based on a Yield Strength of 21,000 psi
- 11. Shock input, 6 directions 11
- 12. Shock response max stress @ mounting foot downward direction 12 Conclusion: Stresses from Shock pulses Are insignificant
- 13. Shock Response max displacement downward shock 13 Max displacement .002 inches Plot magnification = 240,000 X
- 14. Results: Acceleration / Simultaneous Inertial Loads G’s (m/sec sq) 14 Load Case Forward Up Down Side Max Stress Mounting Feet (psi) Material Strength (psi) Factor of Safety Limit Load 2.0 (19.6) 3.07 (30.1) - 1.7 (16.7) 2,500 21,000 8.4 Ultimate Load 3.0 (29.4) 4.6 (45.1) - 2.5 (24.5) 3,250 35,000 10.8 Limit Load 2.0 (19.6) - 6.0 (58.8) 1.7 (16.7) 4,500 21,000 4.7 Ultimate Load 3.0 (29.4) - 9.0 (88.2) 2.5 (24.5) 7,800 35,000 4.5 side up forward
- 15. Results: Acceleration / Simultaneous Inertial Loads G’s (m/sec sq) 15 Load Case Forward Up Down Side Max Stress Fiber Bracket (psi) Material Strength (psi) Factor of Safety Limit Load 2.0 (19.6) 3.07 (30.1) - 1.7 (16.7) 250 11,000 44 Ultimate Load 3.0 (29.4) 4.6 (45.1) - 2.5 (24.5) 350 27,000 77 Limit Load 2.0 (19.6) - 6.0 (58.8) 1.7 (16.7) 450 11,000 24 Ultimate Load 3.0 (29.4) - 9.0 (88.2) 2.5 (24.5) 675 27,000 40 side up forwardMax displacement = .002 inches
- 16. Results: mounting bolt analysis 8 places 16
- 17. • The electronics assembly design concept is structurally adequate for the specified environments. • The maximum stresses and displacements occur during combined acceleration. • The stresses are below the yield point of 6061-T4 for all load cases. • Shock Load stresses are Insignificant. • The assembly main mounting bolts need to have a yield strength >= 100,000 psi Conclusions 17