Structural Reliability Audit: Reverse Engineering of Suspension Component

The initial phase involved precise interpretation of the legacy engineering drawing data, translating the 2D views, dimensions, and material specifications into a digital design intent. This audit established the critical structural features and material properties required for accurate simulation setup.

Generated the high-fidelity CAD geometry in SolidWorks directly from the interpreted drawing data. This reconstruction was essential for establishing a reliable digital twin that accurately represented the original component’s complex structural curves and dimensions for subsequent analysis.

Generated a highly refined finite element mesh, optimizing element size and quality specifically across the critical load-bearing regions and fillets. This preparation was crucial for ensuring the accurate capture of stress gradients during the static analysis without introducing computational error (S_R4).

Applied realistic operational constraints derived from automotive standards, including fixed supports at the pivot points and the specified maximum dynamic load conditions. This established the virtual testing environment to simulate the worst-case scenario for structural integrity verification (S_R4).

Executed the ANSYS solver, then extracted and post-processed the critical stress results, calculating the final Factor of Safety (FOS) against the material yield strength. This documented the design’s margin of error and structural compliance (S_R5).

Delivered the complete simulation project files, the verified CAD geometry, and a formal report detailing the structural audit and FOS verification, confirming the component’s structural reliability under extreme conditions.