Fedél mintafeladat – Femap v11

Finite Element Analysis

Femap v11

By János DEVECZ
(2018)

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 1. Finite Element Analysis Overview

General Steps of Finite Element Method

• Create a proper CAD model and prepare the model for FEM
• Discretize the continuum (Meshing) and select Element Types
• Select Interpolation Function (linear, quadratic, etc.)
• Define the Strain/Displacement and Stress/Strain relationships
• Set the Boundary Conditions (Loads & Constraints)
• Solve the Global Equation System  Displacements
• Compute Additional Results

Basic Equation of Finite Element Method

Where:
K u  F u  K F 1 K Stiffness-matrix (constant)
u Nodal displacement vector
F External nodal force vector

In case of elastic material behavior the stress can be calculated by applying the Hooke-law.|2
The equivalent stress (regarding the principal stresses and directions) can also be calculated.
2. Femap Software Overview

Menubar

Toolbars
Model information

Work area
Bottom tabs
Side tabs

WCS WCS: 0,0,0

Entity editor
Messages area

Status line
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2.1 Femap Basic Settings (1)

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2.2 Femap Basic Settings (2)

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2.3 Femap Basic Settings (3)

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THE END

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Shaft FEM Analysis (Bending & Torsion)

Femap v11 Example

By János DEVECZ
(2018)

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 Pulley-drive arrangement with (simplified) loads
Force equilibrium:
Ft = 2Tnom /D
Ft
D = 212 mm

Ft
F

belt-force Transmitted torque:

Tnom
Ft Tnom = 160 Nm
F
Belt Force:
Ft ≈ 1500 N

Ft Shaft Tension Force:

belt-force F ≈ 2Ft = 3000 N

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 FEM analysis: Large pulley Shaft loads
Large pulley shaft

Tnom

Tension force  Bending F = 3000 N

Torque  Torsion (moment) Tnom = 160∙103 Nmm

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 3D model of Shaft (Solid Edge)

Filename: shaft.par

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 Technical drawing of Shaft (Solid Edge)

Geometry dimensons: d = 25 j6 mm | D = 40 mm | l = 42 mm | L = 62 mm | lret = 32mm

Surface roughness: Ra,shaft = 1.6 mm | Ra,shoulder = 3.2 mm
Material (Femap): AISI Carbon Steel 1025 Cold Drawn

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 Finite Elements Analysis of Shaft (Femap)

•Import Geometry and Save the FEM model

File -> Import ->

Geometry…
{shaft.par}
|OK|
File -> Save
{shaft.modfem}
|OK|

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•Preparation of Model surfaces: Surface splitting

Geometry -> Curve –From

Surface -> Parametric
Curve…

Select Surface for

Parametric Curve: (Select
the half cylinder (1))
Method^ : On Point
Select Location for  
Parametric Curve: (Select
the point (2)) 
() V-Direction
|OK| |Cancel|

(Repeat for surface (3) and
point (4), and the back half
cylinder 2x)

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•Preparation of Model surfaces: Surface splitting – Result

(The yellow surfaces on the

pictures show the splitted
surfaces)

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•Meshing the Geometric model

Mesh -> Geometry ->

Solids…

Material: AISI Carbon Steel

1025 Cold Drawn
|OK|

Midside Nodes [<NO>]

|Update Mesh Sizing…|

Element Size: [3]
(Size in mm)

|OK|

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•Defining the Constraints

Model -> Constraint ->

Set…
ID [1] Title: [fixation]
|Done|

Model -> Constraint -> On

Surface…

(Select the yellow surface on

the picture)

Title: [fixed]
Standard Type: () Fixed
|OK|
|Cancel|

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•Defining the Loads – Bending

Model -> Load -> Set…

ID [1] Title: [loads]
|Done|

Model -> Load -> On

Surface…

Entity Selection: (Select the

yellow surface on the picture)
|OK|
Title: [bending]
Force
Direction:
() Components
FX [3000], FY [0], FZ [0]
(Force Components in N)
(Listen to the sign of Force!)
|OK| |Cancel|

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•Defining the Loads – Torsion

Model -> Load -> On

Surface…

Entity Selection: (Select the

yellow surface on the picture)
|OK|
Title: [torsion]
Torque
Direction:
() Magnitude only
Magnitude [160000]
(Torquee Magnitude in Nmm)
(Listen to the sign of Torque!)
|OK|
Base: X [0] Y [0] Z [0]
Tip: X [0] Y [1] Z [0]
|OK|

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•Setting the analysis parameters and start analysis

Model -> Analysis…

|New…|
Title: [bending and torsion]
Alalysis Prog.: 36..NX
Nastran
Alalysis Type: 1..Static
|OK|

|Analyze…|

|Done…|

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•Show results – Deformation and Von Mises Stress

View -> Select…

Deformed Style:
() Deform
Contour Style:
() Contour
|Def. and Contour Data…|
Output Sets:
[1..NX NASTRAN Case 1]
Output Vectors:
Deform:
[1..Total Translation]
Contour:
[60031..Solid Von Mises
Stress]
|OK| |OK|

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THE END

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 Fedél mintafeladat – Femap v11
Tube Cap Finite Elements Analysis

Femap v11 Example

By János DEVECZ
(2018)

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1.1 Example – Tube Cap

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1.2 Example Overview – Assembled Parts (Cut View)

Cap

Bolt

Internal Gasket
Pressure
Tube-flange
Washer

Hex Nut

Loads
• bolt pretension and pressure
Constraints
• friction and interference fit
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1.3 Tube Cap Overview – Applied Loads & Constraints

Fe = 20 kN (4 x)
(bolt pretension)

Friction area (4 x)
(fixed in all directions)

Equivalent cylinder
(pressure volume)

Flange (transitional fit)

(constraint only radially)

p = 10 MPa (3 x)
(internal pressure)

Loads
• bolt pretension and pressure
Constraints
• friction and interference fit | 4
2.1 Import Geometry

File name: Cap.par

Cap.par

Cap.par

The choice depends on the

Units, set in CAD software!
(Unit in CAD & FEM = mm)
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2.2 Views – Geometry (model)

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3.1 Geometry Preparation – Define Washer

Washer (circular area around a hole)

• effect surface of bolt pretension
• effect surface of friction

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3.2 Geometry Preparation – Define Washer (top)

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3.3 Geometry Preparation – Finished Washer (top)

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3.4 Geometry Preparation – Define Washer (bottom)

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3.5 Geometry Preparation – Finished Washer (bottom)

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3.6 Geometry Preparation – Exit Washer Command

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4.1 Meshing – TetMesh

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4.2 Meshing – Open Material Database

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4.3 Meshing – Select Material (X-40 Cast)

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4.4 Meshing – Material Confirmation

[MPa]

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4.5 Meshing – Set Avgerage Element Size

Avg. element size

[mm]

No Midside Nodes necessary | 17

4.6 Meshing – Finished Mesh

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5.1 Loads – Create New Dataset (1)

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5.2 Loads – Create New Dataset (2)

Loads

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5.3 Loads – Create New Dataset (3)

1..Loads

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5.4 Loads – Applying (On Surface)

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5.5 Loads – Select Washer Surfaces (top)

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5.6 Loads – Set Force value – Bolt (Z)

Bolt (Z)

[N]

[4 x]

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5.7 Loads – Select Dome Surfaces (inner)

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5.8 Loads – Set Prerssure value – Pressure (p)

Pressure (p)

[MPa]

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6.1 Constraints – Create New Dataset (1)

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6.2 Constraints – Create New Dataset (2)

Constraints

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6.3 Constraints – Create New Dataset (3)

1..Constraints

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6.4 Constraints – Applying (On Surface)

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6.5 Constraints – Select Washer Surfaces (bottom)

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6.6 Constraints – Set Constraint values – Bolt (FIX)

Bolt (FIX)

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6.7 Constraints – Select Flange Surfaces (two half)

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6.8 Constraints – Set Constraint values – Flange (RAD)

Flange (RAD)

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7.1 Define Analysis Type

<optional name>

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7.2 Run Analysis

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8.1 Results – Select Deformed and Contour Data

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8.2 Results – Set Contour Options

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8.3 Results – Show Stresses (von Mises)

[MPa]

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8.4 Results – Define Cutting Plane (1)

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8.5 Results – Define Cutting Plane (2)

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8.6 Results – Select Cutting Plane

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8.7 Results – Set Contour Options

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8.8 Results – Show Stresses (von Mises) (Cut)

[MPa]

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9.1 Global Remeshing – Delete Old Mesh (1)

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9.2 Global Remeshing – Delete Old Mesh (2)

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9.3 Global Remeshing – Define New Mesh – TetMesh

Geometry (model) Show/Hide

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9.4 Global Remeshing – New Average Element Size

New Avg. Element Size

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10.1 Local Remeshing – Meshing Toolbox

According to Curve(s)

Increase Nodes

Number of Elements
Multply by Factor
Equal Spacing

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10.2 Local Remeshing – Using Curves

Select Curve(s) to Remeshing

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10.3 Local Remeshing – Remeshed Regions

No. of Nodes, No. of Elements

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11.1 ReAnalysed – Show Stresses (Von Mises)

Analyse [MPa]

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11.2 Nodal Stress (Von Mises) inquiry (1)

[MPa]

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11.3 Nodal Stress (Von Mises) inquiry (2)

[MPa]

Examined
Node

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12.1 Convergence Curve – Overview

Steps to Convergence Curve:

1. Designate an examined point (preferably geometric point)

2. Meshing + Analyze  Note the number of Elements (E) and

Stress () at the test point (Node)

3. Refine mesh + Analyze (with unchanged boundary conditions) 

Note the number of Elements (E) and Stress () at the test point
(Node)
4. Repeat the step 3 as often as necessary
5. Plot the corresponding number of Elements and Stress pairs in

the E- coordinate system

6. Fit the convergence curve to the points
7. The asymptote of the fitted curve will be the accepted Stress | 55
 12.2 Convergence Curve – Plot
5
~78 MPa Accepted range 5
4 red,4=76.4 MPa red,5=78.7 MPa
Von Mises
Stress 3 red,3=75.1 MPa
4 [MPa]

2 red,2=70.3 MPa
Convergence-curve

f ( x )  a  b  e  c x
3

a = 77.567249
2 b = 599.61779
c = 0.00049989295
1 red,1=56.5 MPa

1
No. of Elements (E)

Examined Node Mesh1; E=6715 Mesh2; E=8664 Mesh3; E=11734 Mesh4; E=15312 Mesh5; E=21983

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THE END

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Connecting rod Buckling Analysis

Femap v11 Example

By János DEVECZ
(2018)
Air compressor – Connecting rod (3D View)

Connecting rod
Air compressor – Conecting rod (Cross Section View)

Connecting rod
Connecting rod (3D model)
The buckling (Experiment)
The buckling is an instability, leading to a failure. It is a sudden failure of a part subjected to
high compressive stress, where the actual compressive stress at the point of failure is less than
the ultimate compressive stresses that the material is capable of withstanding.

Pcr Pcr Pcr Pcr

The buckling (Theory)

Pcr Pcr Pcr Pcr Pcr Pcr

Connecting rod (Material, Load and Constraints)
Material: 70 Ni (with Chromium) Wrought

F = 20000 N
Constraints: Constraints:
TX, TY, RX, RZ TX, TY, RX, RZ

Deformed shape Required safety factor

(mechanical model) against buckling:
Undeformed shape
(mechanical model) SFreq = 6 ~ 10

Constraint: Constraint:
Pinned – Pinned –
No Translation No Translation
THE END
Crankshaft Modal Analysis

Femap v11 Example

By János DEVECZ
(2017)

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Resonance (theory)
The resonance is a tendency of a system to oscillate with greater amplitude at some frequencies than at others.
Frequencies at which the response amplitude is a relative maximum are known as the system's resonant frequencies or
resonance frequencies. At these frequencies, even small periodic driving forces can produce large amplitude oscillations,
because the system stores vibrational energy.

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Crankshaft Torsional Vibration
Torsional vibration is a concern in the crankshafts of internal combustion engines
because it could break the crankshaft itself; shear-off the flywheel; or cause
driven belts, gears and attached components to fail, especially when the
frequency of the vibration matches the torsional resonant frequency of the
crankshaft. Causes of the torsional vibration are attributed to several factors.

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Air compressor - Crankshaft

Crankshaft |4
Crankshaft (modal analysis)

Constraint: Constraint: Constraint:

No Rotation Radial Growth mechanical model Radial Growth
of crankshaft
(undeformrd)

Fy (force)
bearing

Z
bearing
Y

X
Fy = 20000 N
Resonance Frequencies [Hz]  Critical Rotational Speeds [1/min]
Critical Frequency Range =  10...15 % of Resonance Frequency |5
THE END

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