Mechanical FEA for Device Shaft Optimization

I have designed a device consisting of several discs mounted on a horizontal shaft. The complete assembly rotates slowly while partially/substantially immersed in water.

I am looking for an engineer experienced in mechanical FEA / shaft design to evaluate the current design and help optimize a new lightweight shaft.

Phase 1 – Analysis of the existing shaft

The current shaft is made of stainless steel.

The objective is to simulate and determine:

- Shaft deflection under the weight of the discs and other components
- Stresses caused by bending and motor torque
- Combined bending + torsional stresses
- Shaft deformation and safety factor during normal steady-state operation
- Loads and stresses during motor start-up and stopping, including maximum transient torque

The simulation should represent the actual shaft supports/bearings and the distribution of the discs along the shaft.

Phase 2 – Design and comparison of alternative shafts

The objective is then to evaluate alternative materials and shaft geometries in order to reduce weight while improving mechanical performance.

For each relevant solution, I would like to compare:

- Maximum shaft deflection
- Maximum stress / strain
- Torsional deformation
- Safety factor
- Weight
- Performance during start-up, steady-state operation and stopping

The new design should have lower deflection than the existing stainless-steel shaft and sufficient safety margin under all operating conditions.

I can provide the 2D scheme, dimensions, material information, disc weights, bearing positions, rotational speed and operating conditions.

Expected deliverables

- FEA results for the existing shaft
- Comparison of relevant alternative materials/designs
- Deflection, stress and safety-factor results
- Short engineering report explaining assumptions, boundary conditions and conclusions
- Simulation files