Abstract

The increasing complexity and performance expectations of modern mechanical systems necessitate a more robust approach to design that prioritizes reliability from inception. This paper presents a conceptual framework that integrates Finite Element Analysis (FEA) with Design Failure Mode and Effects Analysis (DFMEA) to achieve a reliability-centered design (RCD) methodology for mechanical components. While FEA enables engineers to predict stress distribution, deformation, and fatigue life under simulated loading conditions, DFMEA offers a structured pathway for identifying potential failure modes, their causes, and mitigation strategies early in the design cycle. The integration of these two techniques ensures that both physical and functional weaknesses are addressed proactively. The proposed framework adopts a closed-loop design validation strategy where insights from FEA are continuously fed into the DFMEA process to enhance the prioritization of risks based on severity, occurrence, and detectability. In turn, DFMEA findings guide design modifications, which are subsequently validated through iterative FEA simulations. This synergistic loop allows for real-time optimization of component geometry, material selection, and load-bearing capacity while systematically reducing failure risks. Key features of the framework include a reliability scoring system, decision-support metrics, and traceability of design changes linked to risk mitigation. Case applications in the automotive and aerospace industries demonstrate the utility of the framework in improving component durability, extending service life, and reducing warranty claims. Additionally, the paper discusses the integration of this framework within Product Lifecycle Management (PLM) systems and the potential for automation using machine learning to predict high-risk regions based on historical data. By bridging the gap between virtual prototyping and risk assessment, this conceptual framework enables a shift from reactive to proactive design strategies. It provides design engineers, quality managers, and product developers with a unified tool to enhance reliability, safety, and cost-effectiveness in mechanical systems development.