The goal was to design an aluminum structure that would deflect 0.5in under a 200lb load and have a spring constant of 400. Finite element analysis was paired with a mathematical validation using the strain-energy method (Castigliano's Theorem) during the design process. The final results of testing are shown below.
| Estimate Using Strain Energy | FEA Estimate | Actual Testing Results | Target Value | |
|---|---|---|---|---|
| Spring Constant, k | N/A | 364 at yield point, 400 at 200 lb load | 373 | 400 |
| Load at 0.5 in Deflection, lb | 200 | 200 | 200 | 200 |
| Deflection, in | 0.4871 | 0.5008 | 0.56825 | 0.5 |