The document discusses using finite element analysis software like Fusion 360 and SolidWorks to analyze static loads on specialized fabricated parts. It describes design considerations for increasing the width of control arms while keeping weight close to factory specs. Material selection of normalized 4130 steel is discussed. The FEA results from three static load tests on a control arm design are presented, showing von Mises stresses remain below yield strength, allowing fabrication to proceed.

1. FINITE ELEMENT ANALYSIS
STATIC LOADS RELATIVE TO SPECIALIZED PART FABRICATION

2. PROGRAMS USED
• Fusion 360
• Utilized for personal work
• Material selection
• Verification for purchasing material and fabrication
• SolidWorks
• Required course work for MET students at Oregon Tech
• Presentations required and proficiency required for advancement in MET program.

3. DESIGN CONSIDERATIONS
• Increase track width 3.25in. (8.255cm)
• Overall width increases 6.5in. (16.5cm)
• Keep weight relatively close to factory control arms.
• 4xxx series steels
• Normalized 4130 commonly used for these applications
• Delete factory ball joints and use Uniball
• This may be tricky for the lower arm.
• May have to integrate factory lower ball joint into new control arm
• Possibly modify spindle to accept lower Uniball?
• Focus on part availability

4. MATERIAL SELECTION
• Normalized 4130 (Plate)
• Tensile Strength (Ultimate): 97,200 psi
• Tensile Strength (Yield): 63,100 psi
• Alloying Elements
• Chromium (Cr) and Molybdenum (Mo)
• This isn’t horribly important for this projects.
• Grain Boundaries and FEA
• Nodes in FEA (data points)
• Specified points of interest (sensors)

5. FEA VON MISES STRESS
• Structural FEA results look at displacement and stresses
• User has to interpret results to analyze “pass” or “Failure”
• Commonly used to present results of structural safety for many engineering materials
• P. M. Kurowski, 2012.
Google ImagesGoogle Images

6. DRAWING (SHELL 3.175)

7. FEA TEST 1 (STATIC)
• MATERIAL: 4130
• FORCE: 10,000N
• NODES: 23570
• FIXED

8. VON MISES STRESS

9. FEA TEST 2 (STATIC)
• MATERIAL: 4130
• FORCE: 5000N
• NODE: 25102
• Fixed

10. VON MISES

11. FABRICATION
• Satisfied with the results
fabrication can began.

13. FEA TEST 3 (STATIC)
• Load applied is greater than
load received in application
• For demonstration purposes
only
• Fabrication can began

14. FABRICATION
Lay out and clearly mark parts prior to fitting

16. • These slides have been pulled form various presentations during my time at Oregon
Tech. Along with personal project(s) currently underway.
• Resources for technical information were found in required course text(s)
• NOTE: Fabrication and material selection were not required for course completion.
These examples (slides 11-12, 14-15) are personal work and have no connection to, or
affiliation with Oregon Tech or its staff. They are used for illustrative proposes,
highlighting the engineering process and how technology can save time and money.
Important