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Load and Displacement Of An Injection Molded Housing
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KPG is a Biomedical Design Engineer, Computational and Experimental Mechanics Specialist, Engineering Failure Analysis with world-class expertise in engineering design and analysis services in biomedical device design, product design, analysis, test protocols, design verification tests and product documentation for FDA IDE submission of novel biomedical devices. Finite element and computational fluid dynamics analyst for design and analysis of various products requiring non-linear materials.
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Injection molded instrument housing is designed to be hand held. The housing consists of a thin wall, injection molded shell, stiffened with internal ribs and bolt standoffs. The top surface contains a large opening with a thickened edge.
Problem:
The design is intended to survive normal handling loads, as well as impact with other objects and being dropped from a specified height. The injection molded material has an elastic modulus of 1250 Ksi, which is linear elastic up to a yield stress l of 25 Ksi, then follows a yield curve to ultimate at approximately 60 Ksi.
Additional design challenges:
- design is weight critical, need to optimized amount of material used
- housing is hand held, human factors issues govern handle design
- lead time for purchase and fabrication of injection molds
- produced item cost of materials
- produced item manufacturing cost
- time to market schedules
Solution:
CAD software was used to develop the basic 3-dimensional housing concept. MSC-Patran was used to develop the finite element analysis (FEA) model, Figure No.’s 1 through 3, using the software auto-meshing capability. The model mesh consists of approximately 33,000 ten nodded tetrahedral solids, and 64,000 nodes. Model generation time was approximately 10 minutes wall clock time.
The FEA analysis was performed using the MSC MARC software, which incorporated the non-linear material characteristics, loading was incrementally applied to the bottom left surface of the housing, and support constraints applied to the housing handle.
Figures 4, 5 & 6 illustrate the overall displaced shape and displacement distribution in the housing. Von Mises equivalent stress distributions on the displaced geometry are shown in Figure 6, with the interior stress distributions provided in the cutaway view provided in Figure 7.
The FEA results provide information regarding the maximum stress level locations and deformed geometry inherent in the proposed design. The analysis also forms a roadmap for redesign efforts needed to correct and eliminate high stress failure points in the design geometry. The short turnaround time for the meshing and analysis allows the designer to meet tooling design and time to market criteria.
Figure No. 1 - Finite Element Mesh - Side View
Figure No. 2 - Finite Element Mesh - Top View
Figure No. 3 - Finite Element Mesh - Cut Away Interior View
Figure No. 4 - Side View - Deflected Shape
Figure No. 5 - Top View - Deflected Shape
Figure No. 6 - Isometric View - Deflected shape
Figure No. 7 - Isometric View - Von Mises Stress Distribution
Figure No. 8 - Isometric Cut-away View - Von Mises Stress Distribution
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| Biomedical Design Engineer, Computational and Experimental Mechanics Specialist, Engineering Failure Analysis, engineering design and analysis services in biomedical device design, product design, analysis, test protocols, design verification tests and product documentation for FDA IDE submission of novel biomedical devices. Finite element and computational fluid dynamics analyst for design and analysis of various products requiring non-linear materials. | |
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Kevin Kennedy & Associates, Inc.
Rapid Response Engineering® Solutions
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Indianapolis, Indiana 46268
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