Weight Optimization of An Impact Socket

The Client:

A leading manufacturer of impact sockets.


To optimize the design of an impact socket with respect to weight using FEA Analysis.

Client Expectations:

Client expected about 20% of weight reduction for an optimized design which we provided with the help of simulation methodology. FEA Analysis methodology was used to minimize the weight while meeting with the design criteria.

FEA Analysis Project Challenges:

The project required creating 3D model of an impact socket in FEA Analysis model and analyzing the same. It required our FEA experts to prepare a parametric FEA Analysis model using which they can simulate various combination of FEA Analysis for different geometries.

FEA Analysis Project Deliverables:

FEA Analysis Project deliverable were embedded in the form of a detailed FEA Analysis report which included sections such as material used in FEA Analysis model, Meshing parameters details for the FEA model and boundary conditions applied for the FEA Analysis.



FEA Analysis of Impact Socket

FEA Analysis Project Benefits:

The project saved the client overall ofapproximately 60000 USD which includes the manpower and Testing resources required. In addition to this, it also provided an optimized design with minimum weight thanks to FEA Analysis. The methodology of FEA Analysis also imparted a learning to the knowledge base for the client which they can use for different product ranges. All of our FEA Analysis Project Team (FEA Analyst, FEA Consultant and FEA Analysis Lead) could learn the aspect of power tooling and the over-design aspects in this industry thanks to FEA Analysis.

FEA Analysis Project Hours:

  • FEA Analysis Model Preparation: 12 Hours
  • FEA Analysis Solving Time: 10 Hours
  • FEA Analysis Results Discussion: 4 Hours
  • FEA report preparation: 2 Hours

FEA Analysis Project Duration:

  • 3 days

FEA Analysis Project Team:

  • FEA Analyst
  • FEA Consultant
  • FEA Analysis Lead

Customer Delight Experience:

The client expected us to complete the FEA Analysis project within 10 working days which we delivered in 3 working days. Our FEA experts examined the project both from Power Tools domain and FEA Analysis aspects. Our FEA analyst had referred a lot of literature related to the design of Impact Sockets and incorporated the learnings into the FEA Analysis report. Our FEA Consultant conducted a critical assessment of the FEA Analysis report and provided his feedback to include as recommendation for design to the client. The systematic approach and methods to conduct the FEA Analysis and the professional FEA Analysis report were very much appreciated by the client.

Impact Sockets Market Insights:

The increased investments for Automation and robotics are speeding up the demand for power tools and with increased demand, the competition in the power tools market is going to be fierce. For profitability, organizations will look towards optimizing their current products and developing the new products the “optimized” way. FEA Analysis can be effectively used to optimize the designs thus resulting in reduction of weight for the comparable design performance. The optimization for product design will involve team of Design, FEA Analyst, FEA consultants and FEA experts to work on accurate FEA Analysis methods that can predict the product performance.

Similar Areas where FEA Analysis can be useful:

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