Part Optimisation using CNC Milling Techniques and Finite Element Analysis

Aims/Objectives: Increasing demand for optimised, lightweight, and efficient products has become a necessity in the field of engineering. As such, integrating appropriate design processes in engineering education has become crucial for aspiring engineers and practice. In this study, the application of design for manufacturing, finite element analysis, and design for environment principles in the redesign of a motorcycle brake lever was considered. The objective was to enhance its structural performance while reducing material usage compared to the original part. Results: The re-engineered part achieved a significant reduction in mass, minimising its environmental impact, while maintaining an acceptable Factor of Safety (FOS) in comparison to the original design. The Von Mises stress, initially concentrated at a critical arch, was reduced from 54.3 MPa to 27.3 MPa and translated to the pinned region. This effectively eliminated bending moments at critical regions. Additionally, the maximum displacement was reduced, resulting in shorter machining timeframes. Conclusion: Applied systematic optimisation processes demonstrated the possibility of achieving better products with improved safety factors, reduced material usage, and enhanced manufacturing efficiency. The findings and methodologies presented provide critical guidelines for aspiring engineering students and offered valuable insights into the integration of advanced design principles in engineering education and manufacturing.