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Polycarbonate materials display excellent transparency, comparable to glass, while also boasting impressive mechanical properties, including high flexural strength and stiffness. Consequently, polycarbonate serves as a vital substitute for metals and glass, with wide-ranging applications across various fields. However, polycarbonate materials also face challenges, such as stress cracking, frequently leading to performance failures in practical applications, so necessary measures need to be taken to address these issues. Against this background, this paper utilizes finite element analysis (FEA) to perform a mechanical analysis of polycarbonate structural components, aiming to identify fracture points and optimize structural design.The results indicate that this method effectively analyzes stress distribution in polycarbonate structural components and identifies stress-cracking locations. Employing this method, the design of an LED light shell is optimized, leading to a significant improvement in its mechanical properties and the elimination of stress cracking issues. With continuous technological advancements, the performance of polycarbonate materials is expected to further improve, broadening their application potential.
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