Introduction to Finite Element Analysis

1
 Industry 4.0: The Fourth Industrial Revolution

Source: www.aberdeenessentials.com
Industry 4.0: The Fourth Industrial Revolution
Automating the manufacturing processes and the use of other
technologies to make industrial processes more readily accomplished

Nine Technologies Transforming Industrial Production

 Design Thinking Process

Empathize: understanding the needs of the end users.

Define: framing problems as opportunities for creative solutions.
Ideate: generating a range of possible solutions.
Prototype: communicating the core elements of solutions to others.
Test: learning what works and doesn’t work to improve solutions.
 Iterative Design

• Getting it right the first time is hard

• Need better support for quick turn around loop
Source: https://www.ansys-blog.com/additive-manufacturing-nafems/
Simulation Driven Design

Design
Thinking

Iterative
Design

Industry 4.0

Is this just a trend?

 Simulation-Driven Product Development

• This technology is primarily used to reduce time to market

• Reducing the number of necessary prototypes
• Improve quality and robustness of solutions
 Simulation-Driven Design: Benefits

Source: The benefits of simulation-driven design, Aberdeen Group May 2017

 Why Simulation? – Future of Innovation

“If I find 10,000 ways something won’t work, I haven’t failed.

I am not discouraged, because every wrong attempt discarded
is another step forward.”-Thomas Edison

“Success is 1% inspiration and 99% perspiration.”

“Innovation is 1% inspiration and 99% simulation.”

 Why Simulation? – Safety

“Anything that can go wrong, will go wrong”

- Murphy’s Law
 Why Simulation? – Fixing a Flaw

The Rule of Tens

If the cost of fixing a flaw at the design stage is 1
then the cost of fixing during testing is 10
the cost of fixing it during production is 100
and the cost of fixing it if it is only
detected by the end-user is 1000

Simulation allow us to develop design analysis

techniques to fix problems at the design stage.
 Simulation Driven Design
Four types of skills to perform a simulation driven design approach
1. Background in Engineering Science
• Materials Science, Engineering Mechanics, Mechanics of Materials
and Solids, Fluid Mechanics, Thermodynamics and Heat Transfer
2. Understanding of the Computational Methods
• Finite Element Analysis (FEA)
• Computational Fluid Dynamics (CFD)
3. Familiarity with CAD Software
• CAD models are simplified to enable faster simulations
4. Knowledge of Simulation Software
• ANSYS, ABAQUS, SolidWorks, etc
Simulation-Driven Design: Computational Methods

Finite Element Analysis (FEA)

Computational Fluid Dynamics (CFD)

 Finite Element Analysis (FEA)

• FEA is a digital way for predicting how a product reacts to

real-world forces, vibration, heat, fluid flow, and other physical
effects.
• Determine whether a design will fail and, if so, when and how
the material will deform, snap, or collapse.
• FEA does not eliminate the need for prototypes, but it can
shorten the process.
• Often only one or two prototypes need to be built and tested
before anything new goes into production.
• Digital prototyping also allows designers to quickly dig into
more design options.
 Finite Element Analysis (FEA)

A computational mechanics method, Finite element analysis

helps predict the behavior of products affected by many
physical effects, including:
• Mechanical stress
• Mechanical vibration
• Fatigue
• Motion
• Heat transfer
Finite Element Analysis (FEA)
FEA Application: Product Development - Crash Test
 FEA Application: Product Development - Sports

Effect of soccer shoe upper on ball behaviour in curve

19
kicks [1]
Role of simulation in design: Boeing 777

Source: Boeing Web site (http://www.boeing.com/companyoffices/gallery/images/commercial/)

Another success ..in failure: Airbus A380

http://www.airbus.com/en/aircraftfamilies/a380/
FEA: Discretization

Aircraft
Impeller
prepared by: Christian Della 22
Discretization of Finite Element Models
and Types of Finite Elements

prepared by: Christian Della 23

Introduction to the Finite Element
Analysis: Spring Elements

Axial Springs
Stiffness Method

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 Introduction to
FEM
1. Axial Spring

2. Bar Element

3. Truss Element

4. Beam Element

5. Frame Element prepared by: Christian Della 25

 Finite Element Method: Introduction

• The finite element method is a numerical

method for solving problems of engineering
and mathematical physics.
• Useful for problems with complicated
geometries, loadings, and material properties
where analytical solutions can not be obtained.

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 Tensile Testing

Test specimens

Tensile Testing Grips and Fixtures

Machine prepared by: Christian Della 27
 Basic Principles

Step 1: Original shape and size of the specimen with no load.

Step 2: Specimen undergoing uniform elongation.
Step 3: Point of maximum load and ultimate tensile strength.
Step 4: The onset of necking (plastic instability).
Step 5: Specimen fractures.
Step 6: Final length. prepared by:28
Christian Della
Ultimate Tensile Strength, Su
• Maximum possible engineering stress in tension.

Adapted from Fig. 6.11,

Callister 6e.

• Metals: occurs when noticeable necking starts.

• Ceramics: occurs when crack propagation starts.
• Polymers: occurs when polymer backbones are
aligned and about to break.
prepared by: Christian Della 17 29
 Stress-Strain Diagram
• Stress-Strain Diagrams:
Plot of stress vs. strain
for a given material.
• Linear (Elastic) Region:
Region in the stress-
strain diagram where
stress is (generally)
proportional to strain.
• Nonlinear (Plastic)
Region: Region in the Engineering Stress Strain Curve
stress-strain diagram
where stress is not
proportional to strain.
prepared by: Christian Della 30
Stress-Strain Diagram

prepared by: Christian Della 31

 Behaviour of a Single Spring
k

L d
Where : Displacement of Spring
k - spring constant
x - local coordinate direction
F = kd
F - applied force
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 Spring Element
k
node node
1 2
x
f1 ,d1 f 2 ,d 2
L
F = kd
Where :
k - spring constant Stiffness Relationship for a Spring
x - local coordinate direction  f1   k11 k12   d1 
f1 , f 2 - local nodal force  f  = k   
d1 , d 2 - deg ree of freedom
 2   21 k22   d 2 
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 Steps in Finite Element Analysis

1. Discretize and Select Element Type

2. Define a Displacement Function
3. Define Strain-Displacement (ε – u) and Stress-
Strain Relationships (σ – ε)
4. Derive Element Stiffness Matrix and Equations
5. Assemble Equations to Obtain the Global
Equations and Introduce Boundary Conditions
6. Solve for the Nodal Displacements
7. Solve for Element Stresses and Strains
8. Interpret the Results
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 Step 1 - Select the Element Type

k
1 2 F
F
x

d1 d2

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Step 2 - Define a Displacement Function

• Assume a displacement function d

• Assume a linear function
d = a1 + a2 x
• or in matrix form.
 a1 
d = 1 x   
 a2 
• Note: Number of coefficients (a1, a2) = number of
degrees-of-freedom (dof)
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Step 2 - Define a
Displacement Function

Displacement function:
d = a1 + a2 x

Express d as function of d1 and d2.

At x = 0, d (0) = d1 = a1 + a2 (0) = a1
At x = L, d ( L) = d 2 = a1 + a2 ( L) = d1 + a2 L

d 2 - d1
Solving for a2, we have a2 =
L
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 Step 2 - Select a Displacement Function

Substituting a1 and a2 back into d = a1+a2x, yields

 d 2 - d1   x x
d =  x + d1 = 1 -  d1 + d 2
 L   L L

In matrix form:
 x x   d1  Where :
d = 1 -
 L L   d 2  x
N1 = 1 -
L
 d1  x
d =  N1 N2    N2 =
L
d2 
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 Shape Functions
N1 and N2 are called Shape Functions or Interpolation
Functions. They express the shape of the assumed
displacements.

At node 1: N1 =1 N2 =0
At node 2: N1 =0 N2 =1
At any point in the
element:
N1 + N2 =1

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Shape Functions At node 1: N1 =1 N2 =0
At node 2: N1 =0 N2 =1
At any point in the element:
N1 + N2 =1
N1

1 2

L
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Shape Functions
At node 1: N1 =1 N2 =0
At node 2: N1 =0 N2 =1
At any point in the element: N2
N1 + N2 =1

1 2

L
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 At node 1: N1 =1 N2 =0
Shape Functions At node 2: N1 =0 N2 =1
At any point in the element:
N1 + N2 =1

N1 N2

1 2

L
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Step 3 - Define Strain-Displacement and Stress-
Strain Relationships

F = k
 = d ( L) - d (0)
 = d 2 - d1

Where:
F - tensile force
 - total elongation
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Step 4 - Derive the Element Stiffness Matrix and
Equations

f1 = - F f2 = F
F = k = k ( d 2 - d1 ) f 2 = k ( d 2 - d1 )
f1 = k ( d1 - d 2 )

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 Step 4 - Derive the Element Stiffness Matrix and
Equations
Thus, f1 and f2 can be written as
f1 = k ( d1 - d 2 )
f 2 = k ( d 2 - d1 )
In matrix form
 f1   k - k   d1 
 f  =  -k   
 2  k  d2 
The element stiffness matrix [k] of the spring is
k -k 
k =  
Symmetric and Singular
 -k k  Matrix (determinant is zero)
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Step 5 - Assemble the Element Equations to
Obtain the Global Equations and Introduce
the Boundary Conditions (B.C.s)

N
 K  =   k 
 (e)

e =1
N
    
F =  f (e)

e =1

Note: Not simple addition!

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Step 6 - Solve for Nodal Displacements

Obtain :
 F  =  K  d 

Then Solve.

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 Step 7 - Solve for Element Forces

Once displacements at each node are known, then

substitute back into element stiffness equations to
obtain element nodal forces.

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Example 1: Assembly of Element Equation

k1 k2
1 3 2
F
x

1 2

A Two-spring system under axial load

Note:
• Each spring element has 2 DOF
• One degree of freedom at each node in the form
of axial displacement in the x-direction
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 Example 1: Assembly of Element Equation

Continuity or Compatibility Requirement:

Elements 1 and 2 remain connected
at node 3.
d (1)
3 =d (2)
3 = d3
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 Example 1: Assembly of Element Equation

For element 1:  f  =  k  d 
 f1   k1 - k1   d1 
 f  =  -k
Expand Local [k] matrices to Global Size

 3  1 k1   d3 
 f1   k1 0 -k1   d1 
 f  =  0 0 0  d 
 2   2
 f 3   -k1 0 k1   d3 
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 Example 1: Assembly of Element Equation

For element 2 :  f  =  k  d 
 f3   k2 -k2   d3 
 f  =  -k
Expand Local [k] matrices to Global Size

 2  2 k2   d 2 
 f1   0 0 0   d1 
 f  = 0 k  
-k2   d 2 
 2  2

 f 3   0 -k2 k2   d3 
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Example 1: Assembly of Element Equation
Using the method of superposition
 f el1 +  f el 2 =  k el1 +  k el 2   d 

 f  =  K  d  Global Force Matrix

Where the global forces are

F3 = f 3
(1)
+f 3
(2)

F2 = f 2
(2)

F1 = f 1
(1)
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 Example 1: Assembly of Element Equation
 f el1 +  f el 2 =  k el1 +  k el 2   d 

 f1   f1    k1 0 -k1   0 0 0    d1 
 f  +  f  =   0 0 0  + 0 k 
- k2    d 2 
 2  2    2

 f 3  el1  f 3  el 2   -k1 0 k1   0 -k2 k2    d 3 

 F1   k1 0 -k1   d1 
F  =  0 k2 -k2   d 2 
 2  Global Force Matrix
 F3   - k1 -k2 k1 + k2   d3 

 k1 0 - k1 
 K  =  0 k2 -k2  Global Stiffness
 - k1 -k2 k1 + k2  Matrix
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 Example 1: Assembly of Element Equation

Global Force Matrix: Global Displacement Matrix:

 F1   d1 
F  d 
 2  2
 F3   d3 

Global Stiffness Matrix:

 k1 0 - k1 
 0 k2 - k2 

 - k1 -k2 k1 + k2 

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 Properties of [K] Matrix
• Symmetric - both element [k] and global [K]
• [K] is singular. Must apply B.C. to prohibit rigid
body motion.
• Terms on main diagonal are positive Kii and k11
 k1 0 - k1 
 k el1 =  0 0 0 
 - k1 0 k1   k1 0 -k1 
 K  =  0 k2 -k2 
0 0 0   -k1 - k2 k1 + k2 
 k el 2 = 0 k2 -k2 
0 - k2 k2  Global [K]

Element [k] 56
 Example 2

Consider the following 3 spring system

Example 2

Use the following information

k1 = k3 = 100N/mm
k2 = 200N/mm, P= 500N
d1 = d4 = 0

Find
1. Global stiffness matrix
2. Displacements at nodes 2 and 3
3. Reaction forces at nodes 1 and 4
Example 2

Element Stiffness matrices are:

 100 - 100
k =k =  N / mm
 - 
1 3
100 100
 200 - 200
k =  N / mm
 - 
2
200 200
Global stiffness matrix

1 2 3 4
 100 -100 0 0 1
 -100 100 + 200 -200 0 2
K=  or
 0 -200 200 + 100 -100  3
 
 0 0 -100 100  4

 100 -100 0 0 
 -100 300 -200 0 
K= 
 0 -200 300 -100 
 
 0 0 -100 100 
 Example 2
F = Kd
 F1   100 -100 0 0   d1 
 0   -100 300 -200 0  d 
 =  2
P  0 -200 300 -100   d3 
    
 F4   0 0 -100 100   d 4 

Applying bcs, d1 = d4 = 0 yields

 0   300 -200   d 2 
 P  =  -200 300   d 
    3
Example 2

 d 2   P / 250   2 
 d  = 3P / 500  =  3  ( mm )
 3    

Substituting gives forces

F1 = -100d2 = -200N
F4 = -100d3 = -300N
 Example 3

Consider the following 2 spring system

Example 3

Use the following information

k1 = 50N/mm
k2 = 25N/mm, F3= 20N
d1 = 0 and d2=0.75mm

Find
1. Global stiffness matrix
2. Displacements at node 3
3. Reaction forces at node 1
Element Stiffness matrices are:

 50 - 50
k1 =   N / mm
- 50 50 
 25 - 25
k2 =   N / mm
- 25 25 
Global stiffness matrix

1 2 3
 50 -50 0  1
 
K =  -50 75 -25 2
 0 -25 25  3
Example 3

F = Kd
 R1   50 -50 0   0 
 F  =  -50 75 -25 0.75
 2   
 20   0 -25 25   d3 
Applying BCs, d1 = 0 yields
 75 -25 0.75  F2 
 -25 25   d  =  20 
  3   
Example 3

We can move the fixed displacement from LHS to RHS

25d3=20+25*0.75→d3=1.55 (as expected)

Back substituting yields the reaction force at node 1

R1 = 50*0.75=37.5N