PSI - Issue 75

Marco Bonato et al. / Procedia Structural Integrity 75 (2025) 719–729 Author name / Structural Integrity Procedia (2025)

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3.2 FEA results for the Standard PSD reference FEA simulation performed for the standard PSD profile. From Figure 8, the results show a red alert on the flyback (high risk of vibration failure), also the expected average vibration life is 21.35 hours out of the total specification duration (30 hours).

Figure 8. Vibration Fatigue Damage (left) and Life estimated by FEA(right) simulation on the reference PSD input.

Figure 9. Vibration Fatigue Damage (left) and Life estimated (right) by FEA simulation on the ground test.

5. Optimization of the flyback design to manufacturing The representative vibration signal considered for the design validation finds useful application also for another potentiality of modern FEA simulation: the design to manufacturing optimization. By calculating the useful vibration life on the flyback, it is possible to optimize the manufacturing process (and its intrinsic variability) by searching for a design which minimizes the vibration stress on the PCB, with particular attention to the flyback. FEA was used to improve the reliability of the flyback not any design modification but rather focusing the optimization