<![CDATA[The roller assembly is a critical component in a bundling machine that functions to grip and guide materials during the packaging process. Based on operational data, the failure frequency reached 248 units for the nip roll and 124 units for the shaft, exceeding the monthly replacement standards of 160 units and 80 units, respectively. This condition indicates uneven load distribution, which reduces system reliability and increases maintenance costs. This study aims to analyze the stress, strain, deformation, and contact pressure distributions of the existing roller assembly design and evaluate the effect of geometric optimization on the safety factor and fatigue life of the components. The analysis was conducted using the Finite Element Method with ANSYS Mechanical software. The materials used were Polyurethane 80A for the nip roll, ASTM A36 steel for the bracket, and AISI 1045 steel for the shaft. Design improvements were implemented by increasing the nip roll diameter by 20%, enlarging the contact width between the nip roll and the motor roller by 87.5%, increasing the bracket thickness by 50%, and adding a 0.5 mm fillet radius to the bracket. The simulation results showed that the improved design reduced the equivalent stress by 31.2%, equivalent elastic strain by 25.3%, and total deformation by 0.98%. In addition, the fatigue life increased by approximately 431 times, while the safety factor improved by 79,5% compared to the existing design. These results demonstrate that geometric optimization is effective in enhancing the structural performance and reliability of the roller assembly.]]>
