ABSTRACT:
The alternator, a critical component in power generation and automotive electrical systems, relies on robust mechanical design to ensure efficiency and durability. This study investigates the design, material selection, and structural analysis of key mechanical components, including the rotor, stator, bearings, and housing. Advanced finite element analysis (FEA) and computational simulations are employed to assess stress distribution, thermal effects, fatigue behavior, and vibration characteristics under varying operational conditions. The study also explores the impact of load variations, rotational speed, and electromagnetic forces on the overall performance and longevity of the alternator. The results contribute to optimizing mechanical integrity, reducing wear and tear, enhancing energy efficiency, and minimizing maintenance costs. These insights provide a foundation for further advancements in automotive, industrial, and renewable energy applications, ensuring reliable and long-lasting alternator performance.