Overview

Ceiling Mounting Mass Reduction with Ensured Safety is an advanced engineering project that leverages ANSYS Topology Optimization to achieve significant weight reduction while maintaining structural integrity and safety standards. This project successfully demonstrates the application of cutting-edge computational design techniques to optimize ceiling mounting systems for improved efficiency and cost-effectiveness.

The project combines finite element analysis (FEA), topology optimization algorithms, and structural validation to create an optimized design that achieves 7.5% mass reduction (2.5g) from 33.53g to 31.03g without compromising safety factors. This approach represents modern engineering practices in lightweight structural design and optimization with validated results.

Objectives

The primary goal was to achieve measurable weight reduction while maintaining structural integrity and safety standards. The project focused on optimizing material distribution using ANSYS algorithms, conducting stress and strain analysis under various loading conditions, and validating designs through comprehensive FEA to ensure all performance criteria were met. The optimized model successfully achieves a mass reduction of 2.5g (31.03g vs. 33.53g original), representing a 7.5% weight reduction - a significant achievement for lightweighting efforts while maintaining acceptable stress levels and safety factors.

Methodology & Technical Approach

The optimization process followed a systematic workflow combining CAD modeling, finite element analysis, and topology optimization with validated performance metrics:

  • Created initial 3D CAD model with detailed geometry and assembly constraints
  • Established comprehensive FEA setup including mesh generation, boundary conditions, and load applications
  • Defined material properties (Young's modulus, Poisson's ratio, yield strength)
  • Established design space with optimization constraints and non-design regions
  • Applied realistic loading scenarios including dead loads, live loads, and safety factors
  • Used ANSYS topology optimization algorithms to determine optimal material distribution achieving 7.5% mass reduction
  • Performed iterative refinement through multiple optimization cycles with stress validation
  • Conducted detailed stress and deformation analysis (von Mises stress: 46.344 MPa, deformation: 0.03293 mm, safety factor: 5.3944)
  • Validated optimized design with minimal stress increase (3.7%) and negligible deformation increase while maintaining safety requirements