1. Abstract
This study investigates the structural performance of a tablet stand using Finite Element Analysis (FEA). The primary objective is to ensure stability, durability, and optimal material usage. The design is based on a static load of 0.9 kg (≈9 N), considering a safety factor of 1.5–2. The stand is primarily made from Aluminum 6061-T6 sheet metal. The simulation evaluates stress distribution, deformation, and structural integrity while optimizing computational efficiency by using shell elements and shell mesh due to the sheet’s small thickness compared to its length and width.
2. Methodology
Force Calculations
- Mass of tablet: 900 g average has taken by comparing various tablets
- Design load : ≈ 9N
Material Selection
- Form: Sheet metal is chosen due to ease of fabrication and reduced secondary processing.
- Comparison: Solid bodies offer higher load-bearing capacity with compact cross-sections and better integration of functional parts like rolling pins.
Determination of Sheet Metal Gauge
- Reference from Gauge Chart:
- 16-gauge aluminum: 1.29 mm
20-gauge aluminum: 0.81 mm
- Final Choice:
- Given the overhanging span and risk of bending, a thicker gauge is required.
- 9-gauge aluminum (2.9 mm, rounded to 3 mm) is selected for better rigidity and durability.
Material Properties
- Aluminum 6061-T6 is preferred due to its high strength, making it suitable for load-bearing applications.
Mesh Selection
- Shell elements and shell mesh were used due to the sheet metal’s small thickness compared to its length and width.
- This approach reduces computational time while accurately capturing stress and deformation.
3. Observations
- FEA results show low stress values (0.00153 MPa) within material limits.
- The overhanging sections exhibit minimal deformation, confirming the adequacy of 3 mm thickness.
- The stand effectively distributes static loads without excessive bending.
- Shell mesh significantly reduced simulation time without compromising accuracy.
4. Novelty
- Optimized sheet metal design ensures durability while minimizing material usage.
- Thicker gauge selection (3 mm) prevents bending in unsupported spans.
- Use of shell elements and shell mesh improves computational efficiency while maintaining accurate results.
5. Conclusions
- The chosen 9-gauge aluminum sheet (3 mm) is suitable for the design load while ensuring durability.
- Stress values are well within limits, ensuring long-term stability.
- Using shell elements reduced computational time, making the simulation process more efficient.
- Further optimization can explore reinforcing structural supports or material alternatives for weight reduction.
Load Name Load Image Load Details Force.1 Value: 6.24 N, Force X: = -6.24 N, Force Y: = 0 N, Force Z: = 0 N Start Step: Static Step.1 End Step: Static Step.1 Force.2 Value: 6.24 N, Force X: = 0 N, Force Y: = 0 N, Force Z: = -6.24 N Start Step: Static Step.1 End Step: Static Step.1 Restraint Name Restraint Image Restraint Details Clamp.1 Type: Clamp Start Step: Static Step.1 End Step: Static Step.1 Finite Element Model00002244 A.1 Number of Nodes 19240 Number of Elements 8190 Element Type Connectivity Statistics SPIDER 4 ( 0.05% ) TR6 20 ( 0.24% ) TR3 16 ( 0.20% ) POINT 1 ( 0.01% ) NSBAR 2 ( 0.02% ) QD8 5527 ( 67.48% ) QD4 2618 ( 31.97% ) BAR 2 ( 0.02% ) Element Quality Mesh Criterion Good Average Aspect ratio 8181 ( 100.00% ) 1.199 Maximal angle (deg) 7931 ( 96.94% ) 95.095 Minimal angle (deg) 8004 ( 97.84% ) 84.988 Skewness 36 ( 100.00% ) 0.926 Stretch 36 ( 100.00% ) 0.872 Warp factor 8142 ( 99.96% ) 0.055
