FEA‑Based Optimization of Cylindrical Support

About this project

This project applies Finite Element Analysis (FEA) and response‑surface‑based optimization to redesign a steel cylindrical support subjected to a 12 kN bearing load. Using ANSYS Workbench, the study evaluates how varying the web thickness influences structural stress and total mass. A Central Composite DOE and second‑order response surface were used to model the relationship between thickness, von Mises stress, and mass. Optimization was performed with a constraint of ≤35 MPa allowable stress. Results show a clear trade‑off: thinner designs reduce mass but exceed stress limits, while thicker designs improve strength at the cost of weight. The optimal solution was found at 24.25 mm thickness, achieving 33.16 MPa stress and 23.38 kg mass, satisfying safety requirements while minimizing material usage. This project demonstrates practical skills in FEA, parametric modelling, DOE, response surface methodology, and structural optimization, delivering a lightweight and structurally efficient design. Full case study available on Behance: https://www.behance.net/gallery/255252331/FEA-Based-Optimization-of-Cylindrical-Support