Design and Simulation of Mechanical Structures Using FEM (Finite Element Method)

This study applies the Finite Element Method (FEM) to analyse the structural behaviour of a cantilever beam subjected to a distributed load. Using aluminium as the beam material (E = 70 GPa, ν = 0.33), a 3D CAD model was developed in SolidWorks and meshed with tetrahedral elements in ANSYS. The analysis involved defining appropriate boundary conditions, where one end was fully fixed, and a uniform force of 500 N/m was applied at the free end. A linear static analysis was performed to evaluate stress distribution, displacement, and strain energy density. Results indicate that stress concentration is highest at the fixed support, confirming theoretical predictions. The displacement profile follows the expected curvature based on Euler-Bernoulli beam theory. Mesh refinement studies highlight the trade-off between computational cost and accuracy, ensuring convergence of the numerical solution. Additionally, strain energy analysis provides insights for material optimization. The study confirms the reliability of FEM in predicting structural integrity and optimizing mechanical designs. Future research could extend this methodology to nonlinear material behaviour, dynamic loading, and anisotropic materials, further enhancing the applicability of FEM in advanced engineering applications.