Task:

Redesign Hook to minimise its mass

Conditions:

1. You can’t change the shape of the top of the hook or the loaded face

2. You can’t change their positions relative to each other)

3. You can’t change the material

4. You must keep the maximum stress below 207MPa

To reduce the weight I made the hook hollow, and removed material where there is no stress. The stress is concentrated in the curve of the hook, slide 3 shows ribs that help distribute the stress.

Generative Design

The generative design section allows AI to create a body under a specific constraint. the sections of the hook on which the force would be acting on and the constraint. These bodies would be the preserved geometry (green section). After, the section where the AI cannot build through is created. This would be the obstacle geometry (red section). With the force, constraint, materials and manufacturing detail completed Fusion 360 can begin to solve.

Both designs produced through generative design failed, with model 1 having a safety factor of 0.357 and model 2 having a safety factor of 0.247.

Task:

Analyze the heat transfer of 2 brake discs, one with 78 drill holes and one with only 3.

Conditions:

Material

1. Gray Iron

Loads

The loads must be applied in the same area of the disc

1. Thermal load: 200 °C

2. Convection: 38.00 W / (m^2 K) Ambient temperature: 200 °C

Brake disc 1 has a minimum temperature of 173.5 °C, showing a change in temperature of 26.7 °C. The second image shows the temperature of the disc between 190-173.5°C, this further shows how there is little heat transfer through convection.

Brake disc 2 has a minimum temperature of 138.2 °C, showing a change in temperature of 61.8 °C. The second image shows that disc 2 dissipated heat more efficiently than disc 1. Image 3 shows that the distribution of heat flux is larger, with disc 1 having a difference of 0.02264, and disc 2 having a difference of 0.2799. Both have a higher heat flux near their drill hole, meaning more heat is flowing near the drill holes.

This simulation shows how drill holes help dissipate heat from the disc