COSMOS helps minimize deflection of bracket assembly

Company Ingersoll Milling Machine Co. Industry Automotive / Transportation Location U.S.A. Product Used COSMOSWorks Type of Analysis Linear Static More Details

The Challenge
When designing a universal head case bracket assembly for an automotive engine block transfer line, Ingersoll Milling Machine Company wanted to minimize deflection as much as possible. Because the bracket can be used with many different cutting heads, said Scott Riddle, design engineer, "even a deflection of 0.005 inch can be too much, depending on the specific cutter being used."


The Solution
Using SolidWorks to design the bracket assembly and COSMOSWorks to analyze it with the assembly analysis module, Riddle chose to use malleable cast iron, rather than gray cast iron as in the past, and changed the design by adding an extra support to provide additional strength to support the front section of the bracket.

In the final design, with a thrust load of 18,000 lbs on the head, the deflection plot showed just 0.0027 inch deflection. In addition, the final design was more modular than its predecessor.

Summary and Metrics:

• Analysis results obtained in 3 hours instead of 2-3 days
• Optimized the bracket to keep its weight low, while increasing its strength and decreasing deflection.
• The more modular design can be used in many places. The increase in quantity has decreased the average cost per piece. The new design makes it easier for manufacturing, sub-assembly, alignment at final assembly, and also reduces total cost.