ENGINEERING ANALYSIS
Finite Element Analysis
To ensure the durability and performance of our manual scooter, we used Finite Element Analysis (FEA) to optimize the design, allowing it to withstand real-world forces with maximum efficiency
Equivalent (Von-Misses) Stress 1
The simulation results show a maximum von-Mises stress of 574 MPa on small localized area, while the .The enormous range (574 MPa to near-zero stress) implies uneven load distribution, possibly due to sharp geometry changes or improper constraints.
Total Deformation 1
The total deformation analysis of the deck shows a maximum displacement of 171.97 mm, which is excessive for typical deck structures and indicates potential flexibility or stiffness issues. While decks can tolerate more deflection than rigid components, this level of deformation may still compromise safety and usability.
Safety Factor
The safety factor simulation results indicate a minimum safety factor of 0.436 and a maximum of 15, with the critical area showing values close to the minimum. While most regions are extremely safe (SF ≥ 15), the localized zone with SF ≈ 0.436 suggests potential yielding or failure risk under the applied loads, as typical engineering standards require SF > 1. This implies the design may need reinforcement in high-stress areas or a material upgrade if the loading conditions are accurate.
Total Deformation 2
The total deformation analysis reveals a maximum displacement of 0.0492 mm under the applied static loads, with deformation values decreasing progressively to zero in other areas. The minimal deflection demonstrates excellent rigidity in the design, ensuring both operational reliability and user safety.
Equivalent (Von-Misses) Stress 2
The simulation results show a maximum von-Mises stress of 3.19 MPa on the handlebar, which is significantly lower than the yield strength.This means the handlebar is well within safe limits under the applied static loads, with no risk of yielding or failure.
Meshing
Meshing is the process of dividing the geometry into smaller, discrete elements to ensure accurate numerical simulation and analysis in ANSYS. This is our manual scooter meshing for the deck, which enables precise evaluation of stress, deformation, and other critical factors
Functionality
Components
Fabrication
Material Selection
Material selection for our manual scooter is designed with a focus on corrosion resistance, high strength-to-weight ratio, excellent weldability, cost-effectiveness, strong mechanical properties, and ease of manufacturing in demanding environments.
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Pugh Method
Pugh Decision Matrix
Stainless Steel: Best corrosion resistance, durable, easy to maintain.
Mild Steel: Cheap but rusts easily and less durable.
Cast Iron: Strong but brittle, heavy, and prone to rust.
Chosen Material: Stainless steel for better long-term performance.
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Development Cost
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Breakeven Analysis
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