...
Relevant loading notes: For the forces in the Y and Z directions, both vectors are resolved into 1 resultant vector (using trig/pythagoras) and applied this way in the simulation. This is more representative of what is happening in reality and helps to potentially expose stress concentrations not apparent when the Y and Z forces are applied separately. Forces in the positive X direction are applied to a circular split face the same diameter of the spindle head (note not the entire recessed face).
...
Node Size (mm) | Max Stress (MPa) | Location |
|---|---|---|
20 | 194.5 |    |
15 | 192.4 MPa |   |
10 | 192.5 MPa |  |
5 | 193.2 MPa |  |
5mm with 1mm mesh refinement around bolt holes | 177.8 |  |
...
Recommendations and Next Steps
Apply more local mesh refinement to refinements in the model and in all simulation iterations.
Remove rotation lock on bearing cap fixtures.
Run a topology study.
Work on designing a lighter prototype.