Shift Fork Design Optimisation
ES3E5
...
Module Leader: Dr. Ken Mao
School of Engineering
University of Warwick
,Abstract
This report presents the optimisation and validation of a shift fork design using finite element anal-
ysis (FEA), material evaluation, and dynamic assessment. The initial design, made from low carbon
steel, was analysed under operational loading to assess stress and displacement, confirming struc-
tural integrity and a high factor of safety. A mass reduction strategy was implemented, producing a
lighter geometry while maintaining stress and deflection within allowable limits. Material selection
was informed by Granta EduPack, highlighting the suitability of specific polymers and metals, while
also demonstrating that some numerically promising materials were unsuitable due to brittleness
or low yield strength. Mesh convergence studies emphasised the importance of element quality and
aspect ratio, while eigenfrequency analysis and analytical validation confirmed the fork’s robust-
ness against resonant vibration. The study identifies areas for further work, including experimental
validation through tensile, fatigue, and flexural testing, more advanced dynamic modelling, and
refined meshing techniques. Overall, the methodology provides a reliable framework for shift fork
optimisation, ensuring structural performance and potential for lightweighting in future designs.
I
, Contents
Abstract I
List of Figures III
1 Introduction 1
1.1 Design Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Linear Analysis 2
3 Design Improvement and Evaluation 3
3.1 Initial Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Design Iteration 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Design Iteration 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Design Iteration 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Design Iteration 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Design Iteration 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.7 Design Iteration 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.8 Design Iteration 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.9 Design Iteration 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.10 Design Iteration 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.11 Design Iteration 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Mesh Convergence 13
5 Natural Frequency 14
6 Static Validation 15
7 Dynamic Validation 16
8 Material investigation 17
9 Conclusions and Further Work 20
References 21
II
ES3E5
...
Module Leader: Dr. Ken Mao
School of Engineering
University of Warwick
,Abstract
This report presents the optimisation and validation of a shift fork design using finite element anal-
ysis (FEA), material evaluation, and dynamic assessment. The initial design, made from low carbon
steel, was analysed under operational loading to assess stress and displacement, confirming struc-
tural integrity and a high factor of safety. A mass reduction strategy was implemented, producing a
lighter geometry while maintaining stress and deflection within allowable limits. Material selection
was informed by Granta EduPack, highlighting the suitability of specific polymers and metals, while
also demonstrating that some numerically promising materials were unsuitable due to brittleness
or low yield strength. Mesh convergence studies emphasised the importance of element quality and
aspect ratio, while eigenfrequency analysis and analytical validation confirmed the fork’s robust-
ness against resonant vibration. The study identifies areas for further work, including experimental
validation through tensile, fatigue, and flexural testing, more advanced dynamic modelling, and
refined meshing techniques. Overall, the methodology provides a reliable framework for shift fork
optimisation, ensuring structural performance and potential for lightweighting in future designs.
I
, Contents
Abstract I
List of Figures III
1 Introduction 1
1.1 Design Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Linear Analysis 2
3 Design Improvement and Evaluation 3
3.1 Initial Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Design Iteration 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Design Iteration 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Design Iteration 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Design Iteration 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Design Iteration 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.7 Design Iteration 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.8 Design Iteration 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.9 Design Iteration 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.10 Design Iteration 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.11 Design Iteration 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Mesh Convergence 13
5 Natural Frequency 14
6 Static Validation 15
7 Dynamic Validation 16
8 Material investigation 17
9 Conclusions and Further Work 20
References 21
II
