Integrated Finite Element Verification and Thermo-Dynamic Design Evaluation of a ۶۰۶۱-T۶ Aluminum L-Bracket

This rewritten and expanded study presents a verification- and validation-oriented finite element investigation of a cantilevered ۶۰۶۱-T۶ aluminum L-bracket subjected to static service loading, thermal exposure, and harmonic excitation. The bracket represents a common load-bearing component used in machinery frames, instrument mounts, housings, and support assemblies. A three-dimensional solid model was formulated using ten-node quadratic tetrahedral elements, with fixed-base boundary conditions and distributed loading along the hole perimeter to avoid artificial point-load singularities. The study emphasizes a complete engineering workflow: material and geometry definition, mesh convergence, static strength assessment, thermo-mechanical stress evaluation, modal characterization, harmonic response screening, and design sensitivity analysis. Mesh refinement from ۱۵,۲۰۰ to ۲۷۶,۰۰۰ elements showed convergence of peak von Mises stress to ۱۷۵.۲ MPa and tip displacement to ۰.۶۴۸ mm under a ۱.۵ kN reference load. Validation-style datasets for strain, displacement, and impact-test frequencies demonstrated close numerical correlation, with strain discrepancies below ۴.۲%, displacement discrepancies below ۲.۷%, and modal-frequency discrepancies below ۲.۷%. Thermal gradients increased combined stress by as much as ۳۶.۲% relative to the isothermal static case, while excitation near the first bending mode produced significant dynamic amplification. A parametric redesign study further showed that a ۲۰% increase in thickness improved stress, stiffness, and frequency response, whereas a ۵۰% increase in root fillet radius reduced peak stress with minimal mass penalty. The article concludes that reliable finite element assessment requires evidence of convergence, multi-observable validation, service-realistic loading, and the translation of numerical output into practical design decisions.

کلیدواژه ها:

finite element analysis ، aluminum L-bracket ، ۶۰۶۱-T۶ ، mesh convergence ، thermo-mechanical stress ، harmonic response ، modal validation ، design optimization