STATIC ANALYSIS

Static structural analysis revealed significant performance improvements in optimized designs. Among the findings:

• The base model deformed 0.00125 mm under 1350 N, whereas optimized designs showed drastically reduced deformation.

• Design 3 achieved only 0.00023 mm deformation at 1500 N, a 5× improvement.

• Stresses in all optimized designs remained well below the aluminum yield strength, ensuring safety.

• Stiffness improved from 1.08 × 10⁶ N/mm (base) to 5.86 × 10⁶ N/mm (Design 3).

These results confirm that material reduction does not compromise mechanical integrity when executed via topology optimization and generative logic.

MODAL ANALYSIS

Modal analysis determines the natural frequencies critical for avoiding resonance during machining.

Findings show:

• Optimized fixtures possess higher natural frequencies than the baseline model.

• Design 3 consistently exhibits the highest modal stability, indicating exceptional vibration resistance.

• Increased natural frequencies reduce deflection and chatter during CNC milling, improving surface finish and tool life.

These modal characteristics demonstrate that the optimized designs are suitable for high-speed machining.