DESIGN OPTIMIZATION AND FATIGUE LIFE ANALYSIS OF A BICYCLE HEADLAMP MOUNTING BRACKET USING FINITE ELEMENT METHOD

Abstract

This thesis investigates the structural performance and design optimization of a bicycle headlamp mounting bracket using finite element analysis and topology optimization techniques. A CAD model of the original bracket was developed in SOLIDWORKS and analysed under realistic and conservative loading conditions to identify critical stress regions responsible for structural weakness. The results revealed significant stress concentration at the neck region of the original design, indicating inefficient load distribution. To improve the structural behaviour, topology optimization was performed to redistribute material along the primary load paths while reducing unnecessary mass. The optimized design achieved improved stress distribution, reduced peak stress, and a lower mass of 9.209 g while maintaining structural safety with a factor of safety greater than unity. The study demonstrates the effectiveness of simulation-driven design optimization in improving lightweight engineering components without increasing material usage.