Factor of Safety lower than required

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I am currently working on a project for my Thesis and am using Inspire to optimize gears. The attached pic is a screenshot of an optimization where the goal was to minimize mass but keep a SF of 2. The analyzed solution does have a minimal SF of 0.9 though. Why does Inspire not just keep more mass at the place where the SF is too low?




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The high stress happens outside of the design space. Those high stresses are typically taken care of at a later stage of design by more advanced optimization techniques such as shape optimization.

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