Finite Element Analysis (FEA)

Training 2021
INDUSTRIAL APPROACH USING COMMERCIAL FEA/CAE TOOLS
 Part 1
Introduction to FEA/CAE
Engineering Problem
Method To Solve Any Engineering Problem

Analytical Methods Numerical Methods Experimental Methods

• Classical Approach • Mathematical representation • Actual Measurements
• 100 % Accurate • Approximate, Assumptions • Approximate
• Applicable for ONLY simple • Real Life Complicated • Time Consuming & need
problems problems expensive Set up
• Complete in itself • Results must be verified by • Results can not be believed
either hand calculations or by blindly & Min 3 ~ 5 prototypes
Exp. Method must be tested
 What is Analytical Method?
• The word “analytic” is derived from the word “analysis” which means
“breaking up” or resolving a thing into its constituent elements. The
original meaning of the word analysis is to unloose or to separate things
that are together. In this method we break up the unknown problem into
simpler parts and then see how these can be recombined to find the
solution. So we start with what is to be found out and then think of
further steps or possibilities the may connect the unknown built the
known and find out the desired result. It is believed that all the highest
intellectual performance of the mind is Analysis.

• It is derived from the word analysis, its means breaking up.

• It leads to conclusion to hypothesis
• It leads to unknown to known
• It leads to abstract to concrete

Example:
• if a2+b2=7ab prove that 2log (a+b) = 2log3+loga+logb
What is Numerical Method?
Numerical Methods are techniques by which mathematical
Problems are formulated so that they can be solved with
arithmetic and logical operations. Because digital computers
excel at performing such operations, numerical methods are
sometimes referred as computer mathematics

In pre computer era , the time and effort of implementing

such calculations seriously limited their practical use.
However, with the advent of fast, inexpensive digital
computers, the role of numerical methods in engineering
and scientific problem solving has exploded. Basic needs in the Numerical Methods

• Practical : Can be computed in a

reasonable amount of time
• Accurate : Good approximate to true
value
: Information about the
approximate error
What is Experimental Method?
Experimental Method also known as Actual Testing is an actual measurement of physical
testing.
It is applicable only if physical prototype is available.
Min of 3 to 5 prototypes must be tested.
Analytical Method vs Numerical Method vs Experimental Method

Analytical Method Numerical Method Experimental Method

Provide direct solution Can be used with any Testing can only be
and will result in exact function. They often done if we have the
solution if one exists require many physical product.
iterations to get the
true solution
Practical only for Usually is not exact, Costly and time
functions that have a and it is also consuming as the
simple, closed form necessary to provide parts needed to be
mathematical initial estimates of the produced
structure unknown
 What is CAD?
Computer-aided Design:(noun)
The use of computer systems to assist in the creation, modification, analysis, or
optimization of a design.
Essentially, CAD allows you to draw lines and curves in order to build the likeness of a
product, a model you can look at in any direction.
A World Before CAD
Designs were done by hand by drafters
who would draw out the design on paper.
This difficult process took a lot of time.

CAD SOFTWARE
Increases the productivity of the designer,
improves design quality, documents
communication, and creates databases for
manufacturing.

AutoCAD was released in 1982, and by 1994

as many as 750 training centers had been
using it worldwide. Before, drafting required
pencils, erasers, t-squares, and much more
time.
C O N F I D E N T I A L
 What is CAE?
CAE is the use of computer software to simulate performance in order to improve product
designs or assist in the resolution of engineering problems for a wide of industries this includes
simulation validation and optimization of products processes and manufacturing tools.

A typical CAE process comprises of pre-processing, solving, and post processing steps. In the
pre-processing phase, engineers model the geometry and the physical properties of the design,
as well as the environment in the form of applied loads or constraints. Next the model is solved
using an appropriate mathematical formulation of the underlying physics.
 Benefits of CAE
Designs decision can be made based on their impact on performance.
Designs can be evaluated and refined using computer simulation rather than physical
prototype testing saving money and time.
CAE can provide performance insights earlier in the development process, when design
changes are less expensive to make.
The Finite Element Analysis is a computing technique that is used to obtain approximate
solutions of boundary value problems it used a numerical method called as Finite Element
Method (FEM).
FEA involves a computer model of design that is loaded and analyzed for specific results.
History of FEA/CAE
 It was first Introduced in the 1940s
 Sophisticated tool for solving numerous
engineering problems and is widely used and
accepted in many branches of industries.
 Aircraft and aerospace companies, like many
other industries, are dependent on finite
element method. The efficient design of any
modern airplane is impossible without the
technique.
 Indeed, many aircraft components and hence
the total machine are certified and given
certificates through the results of FEM.
 Main History Milestone for FEA/CAE

1941-1942 1956 1959 1960 1965 1977

•Hrennikoff and Courant •Ray W. Clough published •General Motors and IBM •William Fetter from •NASTRAN (NASA •FIESTA, the first
develop mesh the first paper on the build the computer Boeing coins the term Structural Analysis) is professional FEM p-
discretization method for Finite Element Method system DAC-1 (Design “COMPUTER GRAPHIC” developed as structural version code was initiated
solving elasticity and (FEM). Augmented by for his human factors analysis solver tool by Alberto Peano from
structural analysis •The term “FINITE Computers) to facilitate cockpit drawings ISME
problems in Civil and ELEMENTS” was coined the design of cars.
Aeronautical Engineering in a 1960 article.
 Main History Milestone for FEA/CAE

1982 1987 2001 2006 2008 2012

•PROBE, developed by •MECHANICA was •P-version FEM was •ASME Guide for •NASA released a •Barna Szabo and Ricardo
Barna Szabo and Kent developed by RASNA proven to be the most Verification and Validation standard for development Actis introduce
Myers, was the first Corp. efficient for plasticity by A. in Computational Solid of models and “Simulation governance:
‘industrial’ implementation Duster. Mechanics is released. simulations. New technical
of p-version FEA for requirements for software
research and aerospace tools in computational
applications. solid mechanics”.
Typical Equilibrium Problems Suitable for Analysis by Finite Element Method

Aerospace • Stress Analysis of Aircraft Frames, wings, missile and spacecraft components,
Engineering thermal analysis on gas turbine blades, heat exchangers
Automotive • Stress Analysis of crankshaft, cylinder block, connecting rods, chassis, thermal
Engineering analysis of pistons, lubrication of big-end bearings
Biomedical • Stress Analysis of Bones, Hip Replacements, Teeth and Heart
Engineering

Civil Engineering • Stress Analysis of Dams, Retaining Walls, Excavations, Soil Mechanics

Electrical • Steady State Thermal Analysis of Integrated Circuit Boards

Engineering
Hydraulic • Analysis of water seepage and flow under dams, aquifer analysis
Engineering
Mechanical • General 1D, 2D and 3D and Axisymmetric Stress Analyses of Components,
Engineering Stress Analysis of Shafts, Gears and Pressure Vessels, Crack Propagation
Nuclear • Stress Analysis of reactor vessels and structures, thermal analysis of reactor
Engineering components
Structural • Static Analysis of Electricity Pylons, Girders and Bridges
Engineering
Typical Eigenvalue Problems Suitable for Analysis by Finite Element Method
Aerospace • Frequency Analysis of Engine Components, Helicopter Rotor Blades, Gearbox
Engineering Casing, Acoustic Analysis of Aircraft Passenger Compartments

Automotive • Acoustic analysis of passenger compartment and exhaust system, Frequency

Engineering Analysis of Gearbox Casing and Body Shell

Electrical • Natural Frequencies of Printed Circuit Boards

Engineering
Hydraulic • Natural Periods of Lakes and Harbours, Sloshing of Liquids
Engineering
Mechanical • Natural Frequency of Components, Shafts Critical Buckling Loads
Engineering
Nuclear • Neutron flux distribution, Frequency Analysis of pressure Vessels
Engineering
Structural • Natural Frequency and Buckling Loads of Structures, Vibration Analysis of
Engineering Multi-storey Buildings
Typical Propagation Problems Suitable for Analysis by Finite Element Method

Aerospace • Forced frequency Analysis of Aircraft and Spacecraft Components, Thermal

Engineering Analysis of Rocket Nozzles

Automotive • Time dependent Analysis of Engine Components, Pistons, Disc Brakes,

Engineering Exhaust, Crashworthiness of Chassis

Biomedical • Impact Analysis of Skull, Dynamic Analysis of Body and Limbs

Engineering
Civil • Stress Waves in Rock Structures
Engineering
Hydraulic • Transient Seepage and Flow
Engineering
Mechanical • Analysis of Impact Problems, Dynamic Crack Propagation
Engineering
Nuclear • Time Dependant Thermal Analysis of Reactor Components, Shock Spectrum
Engineering Analysis

Structural • Shock and Earthquake Analysis of Buildings and Bridges

Engineering
 What is FEA?
Finite Element Analysis (FEA) is a numerical method for solving problems of
engineering and mathematical physics.

Based On The Idea Of Building A Complicated Object With Simple Blocks, Or

Dividing A Complicated Objects Into Small And Manageable Pieces

• Useful for problems with complicated geometries,

loadings, and material properties where
analytical solutions can not be obtained.

• Finite element results are validated with either

analytical solution or experimental studies.

ELEMENTS
CAE Process Overview
Model from CAD or CAE
Importing CAD file or CAE file
Analysis Type
Material Property
Pre-Processing
Loading
Simulation Setup
Boundary Condition
Mesh Generation
Solving
Altair Solver External Solver

Post-Processing
Result Visualization
Example of CAE Process Flow

Solution Phase
• Part Modelling • Display Result
• Material Properties • Analysis Type • Reporting
• Load
• Boundary Condition
• Meshing
Pre-Processing Post-
Phase Processing
Example of CAE Process Flow
- Real life
 Planning a Solution
Communicate Goals History
Discuss the problem with all Define the project goals as Research the history of the
appropriate people clearly as possible component

Consider Boundary & Systems Time Constraint FEA Feasibility

Form a solution strategy based Be realistic in your Consider the application of
on the operating environment of objectives and approach alternative solutions
the component based on the time available

Plan Element Type & Model Size Review The Plan

Select element types and See the end” before you
number based on timing, begin in terms of final
accuracy, and compute cost results requirements
Terminology of FEA
 Node 1 Dimensional
The nodes / points define the
geometry of the elements and also
define the degrees of freedom.
Each nodes is controlled by
coordinate (x,y,z)

 Element 2 Dimensional
Elements are the building
lines/planes or blocks of a
model, they are used to divide a
given complex physical domain
into simple mathematical
representation (simple shapes)
with known solutions

3 Dimensional
Degrees of Freedom (DOF)
• The unknowns in a finite element problem are referred to as the
degrees of freedom (DOF).

• Degrees of Freedom vary by element and analysis type.

DOF Type Action Application

Displacement Force Structural
Temperature Heat Flow Rate Thermal
Velocity Fluid Flow Rate Fluid
Voltage Electromotive Force (EMF) Electrostatic
 Degrees of Freedom (DOF)
Every nodes in FEM has degree of freedom (DOF).
Number of independent motions that are allowed to the node to move in space.
3 linear movement in (x, y and z) direction ( symbol as U-displacement)
3 rotational movement in (x, y and z) direction (symbol as UR-rotational displacement)

Uy

URy

Ux

Uz URx

URz
Pop Quiz 1
1. What is CAE?

2. What is FEA?

Fix Direction Node Movement direction

Ux, Uy and Uz
Ux, Uz, URx, URy, URz
Ux, Uy, Uz, URx, URy, URz
Uy, Uz, ,URy, URz
Types of Analysis (Brief Introduction)
Linear Static Analysis Fatigue Analysis

Non Linear Analysis Topology Optimization

Dynamic Analysis CFD Analysis

Buckling Analysis Crash Analysis

Motion Analysis NVH Analysis

Thermal Analysis Electromagnetics Analysis

Linear Static Analysis
We can define static state as the state of a
system that is in equilibrium under an action of
balanced forces and torques so that they remain
at rest (V=0).

System is subjected to loads and boundary

conditions like:
◦ Forces, Moments, Temperature, SPC’s (Single
point constraints), MPC’s (Multi point
constraints)…

Analysis has some assumptions like:

◦ Deformations are in the elastic range
◦ Stresses are assumed to be linear functions of
the strains
 Linear Material Properties

Elastic Region

C O N F I D E N T I A L
Linear Static Analysis

Snap fit mechanism

Bracket

Pressure Vessel
Connecting rod
Piston

C O N F I D E N T I A L
Non Linear Analysis
 Non Linear Material Properties
Plastic Region

C O N F I D E N T I A L
Non Linear Analysis
Dynamic Analysis
Linear Buckling Analysis
Some key aspects:
◦ Applicable for only compressive load
◦ Slender beams and sheet metal parts
◦ Bending stiffness <<< Axial stiffness
◦ Large lateral deformation
Output from software : Critical value of load.
Practical applications: Commonly used for civil
engineering applications
Mechanical engineering applications - vacuum
vessel, long gear shifter rod analysis, etc.
Linear Buckling Analysis
Motion Analysis (Multibody Simulation)
Multibody simulation (MBS) is a method of numerical simulation in which multibody
systems are composed of various rigid or elastic bodies. Connections between the bodies can
be modeled with kinematic constraints (such as joints) or force elements (such as spring
dampers). Unilateral constraints and Coulomb-friction can also be used to model frictional
contacts between bodies. Multibody simulation is a useful tool for conducting motion analysis. It
is often used during product development to evaluate characteristics of comfort, safety, and
performance.
C O N F I D E N T I A L
Thermal Analysis

Practical applications: Engine, radiator, exhaust system, heat exchangers, power plants,
satellite design etc.
Thermal Analysis

Electronic Board

Heat Sink
Fatigue Analysis
High-cycle fatigue
◦ Historically, most attention has focused on situations
that require more than 104 cycles to failure where
stress is low and deformation primarily elastic.

The S-N curve

◦ In high-cycle fatigue situations, materials performance
is commonly characterized by an S-N curve, also
known as a Wohler curve.
◦ This is a simplified graph of the magnitude of a cyclic
stress (S) against the logarithmic scale of cycles to
failure (N).
Fatigue Analysis
Optimization Analysis
Optimization Analysis
• In size optimization, the properties of structural elements such as shell thickness, beam
cross-sectional properties, spring stiffness, and mass are modified to solve the
optimization problem.

• Software can’t add or remove geometry but can play with only predefined parameters within
specified limits
Optimization Analysis
• Shape Optimization
‒ Usually restricted to only linear static & normal mode dynamic
‒ Software can give hint for addition or remove of geometry
Optimization Analysis
• Topology optimization:
‒ Optimises material layout within a given
design space, for a given set of loads and
boundary conditions such that the resulting
layout meets a prescribed set of performance
targets.
‒ Topology optimisation is used at the concept
level of the design process to arrive at a
conceptual design proposal that is then fine
tuned for performance and manufacturability.
‒ This replaces time consuming and costly design iterations and hence reduces design
development time and overall cost while improving design performance.
‒ A concern in topology optimization is that the design concepts developed are very often not
manufacturable. Another problem is that the solution of a topology optimization problem can
be mesh dependent, if no appropriate measure is taken.
Optimization Analysis

• Topography optimization
‒ Advanced form of shape optimization in which a design region for a given part is defined and a
pattern of shape variable-based reinforcements within that region is generated.
‒ The approach in topography optimization is similar to the approach used in topology
optimization, except that shape variables are used rather than density variables.
‒ The design region is subdivided into a large number of separate variables whose influence on
the structure is calculated and optimized over a series of iterations. The large number of shape
variables allows the user to create any reinforcement pattern within the design domain instead
of being restricted to a few.
Topography Optimization Analysis
 Computational Fluid Dynamics (CFD) Analysis
Computational Fluid Dynamics (CFD) is the branch of fluid mechanics which uses numerical methods to
analyze fluid dynamics problems.
It is based on the Navier –Stokes equations (Mass, Momentum, and Energy conservation equilibrium
equations).
C O N F I D E N T I A L
Crash Analysis
 Noise, Vibration & Harshness (NVH) Analysis
NVH problems are broadly classified into structure borne and airborne sound.
Practical applications: Computing the sound pressure level is of utmost importance to automobile, airplane,
and aerospace designers as customers always prefer a low noise level. Computing the response at the driver’s
feet ( brake pedal ), mirror mounts , steering column, and seats plays a crucial role as the driver must be
comfortable. Also predicting the sound quality and radiation at a certain distance from the car is important.
Pop Quiz 2
1. Why is there a difference between FEA
and CAE?

2. What CAE solutions that is not using

FEA?
 Broadest Portfolio of Optimization-Enabled Solvers

Manufacturing Crash, Safety,

Systems Simulation Electromagnetics Structural Analysis Thermal Analysis Fluid Dynamics
Simulation Impact & Blast

Altair is driving the design benefits of multiphysics optimization.

 Altair Simulation-Driven Design

Injection
Studio Structures Motion Fluids Casting Forming Extrusion Print3D
Molding

Altair Inspire™
Engineering Senarios
How are we addressing these developments ??
 How Simulation Helps in Resolving Engineering Challenges

Structural Stiffness
Electromagnetics
Control System

Fluid Dynamic
Drop Impact for packaging

Optimization Manufacturing
Advanced Materials
 ORS Technologies

@ors.tech

ORS Tech

VISIT ME ON WEBSITE

www.orstech.com

ORS TECHNOLOGIES SDN BHD (675992-p)

Unit 2-5, MH AVENUE, NO 2, JLN BUNGA KANTAN
OFF JALAN GENTING KELANG, 53300, SETAPAK, KUALA
LUMPUR