Generative Design Effectivity on Belt Conveyor for Additive Manufacturing Using Finite Element Method

Abstract

This research focuses on the optimization of belt conveyor brackets using generative design and finite element method in compliance with industrial needs toward efficiency, economic viability, and sustainability in material handling. Although an indispensable element in conveying bulk materials within industries, belt conveyors still face some problems, including material demand and high manufacturing costs. The following design utilizes generative design technology with Autodesk Fusion 360 2024 and FEM using software ANSYS 2023 R2 for presenting an optimized bracket design in aluminium 6061, which has a good strength-to-weight ratio and is very common. The research methodology was hence a combination of algorithmic design exploration with structural analysis, in pursuit of optimum material distribution with required load-carrying capacities maintained. Using generative design, a great number of iterations of designs were tested against pre-defined performance parameters and constraints. FEM validation was thereafter necessary to check for stress distribution, strain pattern, and deformation character under different loading conditions. The optimized design resulted in an 86.4% volume reduction from 89,317.58mm² to 12,172.8mm², while mass reductions ranged from 0.198 kg to 0.033 kg. The maximum equivalent Von-Mises stress, when a minimum and maximum applied load of 5-30 kg, was 109.95 MPa, way below the yield strength for aluminium 6061, at 276 MPa. The equivalent strain under these increasing loads varied between 0.00029559 to 0.0017735 mm and shear strain from 0.00039804 mm to 0.0023882 mm, which is relatively controlled deformation. Buckling analysis has been done showing good stability with two major modes at 1.0844 mm and 1.0523 mm, while keeping the high load multiplier in first mode from 2085.1 at 5 kg to 347.52 at 30 kg and 3332.3 at 5 kg to 555.38 at 30 kg in second mode. The safety factor of the design was between 13.385 and 2.2308 within the test load confines and thus is reliable for industrial use. These results confirm that generative design optimization can achieve significant material savings with absolutely no compromise on the structural integrity of the industrial conveyor system. That is a good representation of the feasibility of sustainable design for industrial applications without compromising performance and safety.