MARGINAL. Peak 124 MPa on the 3.99 mm inside fillet (face 65) at (43.9, 8.96, 79.6). It survives the load, but the safety factor 1.33 is below the 2 target. Confidence is medium.

Confidence: medium. load introduction: the off part loads enter through a distributing coupling (the attached part adds no stiffness). With a rigid attachment (the attached part does not flex) instead, the governing stress converges to 55 MPa on face 2 at (-34, 0, 29.5) (0.44x, safety factor 3.00) over 3 meshes refined around that peak: 54.2 -> 54.3 -> 55 MPa, last change 1.1%. The verdict depends on this assumption: check how the attached part really carries the load; the verdict depends on how the load enters the part (rigid attachment versus distributed); the answer assumes distributed
Max deflection 0.265 mm at (24.2, 0, 112).
Material Custom material (cast), limit 165 MPa; mass 359 g.
Loads: 2000 N -0.8660254,0,-0.5 at 0,-30,66 @ holes d=6.6. Fixtures: fixed z=min.

Checks:
  [pass] mesh convergence: von Mises stress settled: 122 -> 124 -> 124 MPa over 3 meshes, last change 0.1%
  [pass] force balance: reactions balance the loads to 1e-05% (forces) and 1.2e-06% (moments)
  [skip] hand calculation: no simple beam model applies (the governing point is not between the fixtures and the load, so no single section carries it)
  [pass] singularities: no sharp corner or support artifact is above the reported stress
  [pass] units and sanity: part 203 mm across, peak strain 0.0017, max deflection 0.265 mm (0.13% of size): all plausible
  [warn] load introduction: the off part loads enter through a distributing coupling (the attached part adds no stiffness). With a rigid attachment (the attached part does not flex) instead, the governing stress converges to 55 MPa on face 2 at (-34, 0, 29.5) (0.44x, safety factor 3.00) over 3 meshes refined around that peak: 54.2 -> 54.3 -> 55 MPa, last change 1.1%. The verdict depends on this assumption: check how the attached part really carries the load

Assumptions:
  - Linear elastic material and small deflections (no yielding redistribution, no buckling).
  - Custom material (cast): E 72400 MPa, Poisson 0.33, von Mises vs yield 165 MPa (user supplied; the rest from Aluminum A356-T6 (sand cast)).
  - Loads are static and applied all at once; no impact, vibration or fatigue.
  - Cast part treated as sound and uniform; porosity or shrinkage in thick sections can lower the real strength, which is why castings carry larger safety factors.
  - Fixed faces are perfectly rigid; real mounts flex a little, which lowers peak stress next to them.
  - Remote loads and moments are spread over their faces without stiffening them.
  - Contact between separate parts, friction and preload are not modeled.

Suggested fixes:
  - The wall through the peak is 6 mm. To reach safety factor 2 it needs 7.35 mm (+22%), because bending stress falls with thickness squared.
  - The peak sits where two walls meet and bend. A gusset as thick as the wall, with legs about half as long as the shorter wall, ties them together and usually cuts the corner stress by half or more.
  - Stress stays about the same for the same shape and load, so Aluminum 6061-T6 (276 MPa) gives safety factor 2.23. It is 0.95x as stiff, so deflection scales by 1.05. Other options: Mild steel (ASTM A36) (2.02), Aluminum 7075-T6 (4.07).

Images: stress: images/stress.png, zoom: images/zoom.png, safety: images/safety.png, deformed: images/deformed.png, convergence: images/convergence.png
Report: report.html
