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Automated Fatigue & Durability Assessment of an Automotive Bracket
Project :
A Python-driven finite element workflow for evaluating the structural and durability performance of an automotive-style bracket under displacement-controlled loading.
Using automated post-processing, the study investigates how bracket thickness influences:
stiffness
weight
local stress concentration
fatigue life at critical mounting holes
The workflow combines parametric simulation, hotspot extraction, and fatigue estimation to support early-stage design decisions.
Bracket thickness affect durability, stiffness, and weight in a displacement-controlled scenario.
An answer to
What thickness range provides the best balance between stiffness, structural mass, hotspot stress levels, and fatigue durability in a displacement-controlled mounting scenario?
Fatigue Assessment Approach
extraction of local principal stress at hole-edge hotspots
conversion of peak stress to cyclic stress amplitude
estimation of fatigue life using an S-N / Basquin-type relation
comparison of durability across thickness variations
Parametric Design Exploration
influence of bracket thickness on fatigue durability
trade-off between structural mass and fatigue life
relationship between stress amplitude and durability
effect of thickness on peak hotspot stress at mounting holes
relationship between component mass and structural stiffness
identification of optimal designs using Pareto trade-off analysis
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A parametric design study was conducted to identify an optimal bracket configuration that balances stiffness, structural mass, and fatigue durability.
Durability vs Mass Relationship
Under displacement-controlled loading, increasing bracket thickness increases structural stiffness and reaction forces, leading to higher local stresses at the hotspots. While thicker designs improve structural stiffness, they may reduce fatigue durability and increase component mass. The plot illustrates how structural mass and durability evolve across the thickness design space.
Thicker → higher stress → shorter fatigue life
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