09/11/2025
“When Things Break — What Goes Wrong Before You See the Crack”
“In a recent engagement I reviewed a component that repeatedly cracked under low cyclic loading. The culprit? A combination of insufficient fillet radius + unexpected thermal stress. By re-modelling the geometry in ANSYS and adjusting the radius by 15 % we reduced peak stress by ~20 %.
If your component is giving you grief, sometimes the fix is in the geometry + boundary conditions, not just material swap.
Comment below your toughest failure issue or send me a message — perhaps I can help.
”Interested in a quick audit of your design? DM me for a 15-min discussion.”