330:155g Finite Element

Analysis
Nageswara Rao Posinasetti

1. Introduction
Finite element analysis is a computer-
based numerical technique that is used to
solve stress analysis, heat transfer, fluid
flow and other types of engineering
problems.
Real power is in its ability to solve
problems that do not fit any standard
formula.

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Before FEA

Tested till failure before the availability of

FEM.

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Before FEA
Problems are simplified using certain
approximations before the availability of
FEM.

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1. Introduction
It involves partitioning of a structure into a
finite number of elements
„ Divide and Conquer
Elements are connected to one another at
the corner points
„ These corner points are called nodes or nodal
points
Each element is a simple geometric shape
„ Triangle, Quadrilateral, etc.

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 1. Introduction
In order to completely define a finite
element model
„ Nodal points
„ Elements
„ Loads
„ Supports
„ Element related data

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1. Introduction
FEA program formulates the equations for
solutions
„ A nodal point can have upto 6 degrees of freedom
„ 3 translational (x, y, z) and 3 rotational
„ An equilibrium equation for each degree of freedom
Equations are solved for displacement at each
nodal point
Displacements are then used to evaluate the
stresses

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1. Introduction
For the model to accurately represent the
physical part, the number of elements
should be large.
Type of element should be correctly
chosen
Boundary conditions should be correctly
applied.

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1. Introduction
Process of data preparation is tedious and
long.
„ It is called pre-processing
Results obtained are also voluminous
„ It is called post-processing

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Steps in finite element analysis

process
Pre-processing
Define the model
„ Discretize the part defining nodal points and
elements
„ Define element properties, material properties
such as density, modulus elasticity, etc.
„ Specify the boundary conditions
„ Specify the loads

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 Preprocessor
Modelling of the geometry
Generating the finite element mesh by making a
suitable approximation to the geometry
Calculates the nodes and elemental properties
Allows for the specification of the support
condition and loading conditions for the
individual element positions.
Allows the material properties to be specified.

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 Analysis
Formulates the equations that describe
each elements’ stiffness and assembles all
of the equations so that they form a set of
simultaneous equations
Solves the system of equations for the
displacement at each nodal point
Uses the nodal point displacements to
solve for stress within each element

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Results
Results generated from the analysis are
voluminous depending upon the number of
elements considered.
For proper understanding one has to go
through all the data tables.

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Postprocessor
Post processing involves the ability to go
through a large amount of data generated
during the solving process and convert it
into an easily understood form for the
design purpose.

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 1.2 Library of Element Types
Depending upon the part geometry and
the type of analysis required a number of
different types of elements are available in
FEA

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a) one dimensional

3-node quadratic
2-node linear

Triangular Quadrilateral

b) Two dimensional

3-node linear 6-node quadratic 4-node linear 8-node quadratic

Tetrahedral

c) Three dimensional

4-node linear 10-node quadratic

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 1.3 Advantages of using FEA
Irregular shaped parts
Parts made from different materials
Irregularly placed loads
Large number of supports
Provides results throughout the part (all
points)
Easy to change the model

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Why Use FEA?

Provides a non-destructive
means of testing products.
Faster prototyping for “what
if” scenarios.
Design optimization.
Speed up time to market by
shortening the design cycle.

Courtesy Algor Inc,

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 Best Practices
FEA requires engineering judgment.
„ In the best case, you should know the
approximate answer before you begin.
Proper selection of elements, materials,
loads, constraints and analysis parameters
comes from experience.

Courtesy Algor Inc,

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Best Practices
Understand that the computer model
never matches reality (it’s only an
approximation).
The surest route to failure in FEA is to
underestimate the complexity of the
technology.

Courtesy Algor Inc,

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FEA in Different Industries

Aerospace Industry
Orbital Technologies Corporation
„ The above illustration shows how engineers
analyzed a Biomass Production System to
conduct biotechnology plant research.
Courtesy Algor Inc,
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Pittsburgh

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 FEA in Different Industries

Automotive Industry
Danly Engineering Services, Division of Enprotech
Mechanical Services, Inc.
„ The above illustration shows how engineers analyzed a
power press with additional cutouts. Courtesy Algor Inc,
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Pittsburgh

FEA in Different Industries

Biomedical Industry
Ophthalmic Consultants of Boston and the
Tufts University School of Medicine
„ The above illustration shows stresses on an eye as it
underwent a 30° saccadic eye movement. This was
modeled to help understand why retinal detachments occur.
Courtesy Algor Inc,
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FEA in Different Industries

Power/Utility Industry
Cronulla Sewage Treatment Plant
„ The above illustration shows how engineers modeled a piping
system to verify that the number of bellows could safely be
reduced by using lightweight, spiral-wound stainless steel. This
allowed them to keep a $90 million sewage treatment plant
upgrade on budget.
January 16, 2008 Rao, P.N. Courtesy Algor Inc,
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Pittsburgh

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 1.4 Historical Development
Concept first appeared in 1956
Name “Finite Element” is used in 1960 by
Clough
1970’s large programs running in
mainframe computers
1980’s moved to personal computers and
widespread use

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CAD to FEA
There are many approaches for integrating
CAD systems to FEA

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CAD System
Full
Geometric Pre- FEM model
modeller Processor

FE Mesh FE FE Post
Analysis Processor
CAD
Geometry
FE Pre-
Processor

Inventor to Algor

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 Geometric FE Pre- FE FE Post
modeller Processor Analysis Processor

Integrated FEA System, e.g. Algor

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Design problem
Select a round bar to be constructed from an AISI 1020
cold-drawn steel to support the 300-pound ball. Assume
a safety factor of 2, and determine the deflection for the
size selected
Yield stress = 61,000 psi

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Design problem
Cantilever beam
Max bending moment = 300 x 36
= 10,800 in-lb
Stress in the beam, S = M/Z
S = 10,800 x 32 / (Π d3)
Allowable stress = 61,000 / 2 = 30,500 psi
Equating the above two, and solving
d = 1.533 in = 1.625 in (preferred size)
Deflection = -FL3 / (3EI) = 0.455 in

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 Problem using FEA
Start with 2 in dia; Max stress = 13,751 lower than
the allowable 30,500 psi

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Problem using FEA (contd..)

Next try 1.5 in dia; Max stress = 32,599 higher
than the allowable 30,500 psi

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Problem using FEA (contd..)

Next try 1.625 in dia; Max stress = 25,635 lower
than the allowable 30,500 psi - Acceptable

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 Problem using FEA (contd..)
For 1.625 in dia; Max displacement = 0.47 in
Compare this to analytical solution of 0.455 in, a
3% error

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Analytical Problem Solving Process

Establish clearly defined goal

Compile and qualify the inputs
Solve the problem with the most
appropriate means
Verify and document the results

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What is the goal of the Analysis?

The decisions to be made
How important is the exact solution to the
problem?
„ This will help in identifying the precision of the
inputs to the problem.
What information from the analysis will
help in taking the engineering decision
„ When can you stop analyzing?
„ Which shortcuts are allowed?

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 Common Misconceptions
Meshing is everything
„ Current preprocessor are efficient and generally give
good meshes. But that is not the end since it is only
an input.
„ Boundary conditions and forces are added by the
user. The accuracy of the results depend to a great
extent on them.
FEA replaces testing
„ Depends on the confidence in the analytical methods
used.
„ There is no guarantee that the results are accurate.

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Common Misconceptions
Finite element analysis is easy
„ Don’t underestimate the complexity of the
problem.
„ Don’t jump to conclusions too quickly.
„ Some little experiments may be required to
gauge the forces and reactions in the part.
„ Interpreting the results is also an important
task.

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Common Misconceptions
Finite element analysis is hard
„ It is estimated that 20% creativity and 80%
hard work and patience.
„ Learned through more practice
Learning the interface equals learning FEA

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 Questions or
Comments?

Exercises
Define the terms: nodal point, element and degree of freedom
What does the term discretization mean in the finite element
method?
List three different material properties that must be defined for each
of the element.
Explain why the computer is necessary in the use of the finite
element method.
Explain why computer graphic techniques are used during the post
processing phase of a finite element analysis. What is the alternative
to using these graphical displays?
What advantage would a company derive by performing a finite
element analysis of an existing part, which can be strain gauged and
tested in a lab?

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