Engineering Analysis (EA)

Dr. Ir. M. Sabri, MT. IPM. Asean Eng.

 Methods To Solve Any Engineering Problem

ANALYTICAL METHOD NUMERICAL METHOD EXPERIMENTAL METHOD

- Classical approach - Mathematical representation

- Actual measurement
- 100% accurate results - Approximate, assumptions
-Time consuming & needs
- Hand calculation made
expensive set up
- Applicable only for simple - Results can not be believed
- Applicable only if physical
problems like cantilever and blindly & must be verified by
prototype is available
simply supported beam etc. experimental method or hand
- Results can not be believed
- Complete in itself calculation for knowing the
blindly & min. 3 to 5
range of results
prototypes must be tested
- Applicable even if physical
prototype is not available (initial
design phase) -Strain gauge
-Photo elasticity
FEM/FEA: Linear, Nonlinear, -Vibration measurements
Buckling, Thermal, Dynamic & -Sensors for temp. & pressure
Fatigue Analysis etc.
BEM: Acoustics/NVH -Fatigue test
FVM: CFD
FDM: Thermal & fluid flow
analysis (in combination with
FVM)
Methods To Solve Any Engineering Problem
Numerical Method
TITLE OF PROBLEM <Beam Analysis>
Analytical Method EXAMPLE 1
NN NE NM NDIM NEN NDN
v P 8 7 1 1 2 2
ND NL NCH NPR NMPC
2 1 1 1 0
Node# Coordinates
1 0
x 2 .1
3 .2
4 .3
5 .4
6 .5
a b 7 .6
8 .626
Elem# N1 N2 Mat# Mom_Inertia)

(L −b − x )
1 1 2 1 4.5e-11
Pbx 2 2 2
v=− 2
3
2
3
3
4
1
1
4.5e-11
4.5e-11
6 EIL 4 4 5 1 4.5e-11
5 5 6 1 4.5e-11
6 6 7 1 4.5e-11
7 7 8 1 4.5e-11
DOF# Displacement
Experimental Method 1 0
15 0
DOF# Load
7 -10
MAT# PROP1
1 200e9
Methods To Solve Any Engineering Problem

Results from the analysis

Activity Deflection at loading (mm)

Analytical Method 4.83

Experimental Method 4.55 (6 % error)
Numerical Method 5.03 (4 % error)

Data: P = 1 kg
E = 200 GPa
L = 226 mm
a = 400 mm
Lecture Plan/Assessment
WEEK TOPIC Assignment
1.0 Introduction to Finite Element Analysis (FEA)
1.1 Brief Historical Background
A. Buatkan kembali Aplikasi
1
1.2 Methods Solve any Engineering Problem tegangan statika yang diuraikan
1.3 Design Cycles
1.4 Types of Analyses dari bentuk analitik biasa menjadi
1.5 Advantages of FEA
1.6 Case Study and Project Assignments bentuk numerik menggunakan
2.0 FEA Strategies and Analysis
2.1 Methods and Procedures in FEA
FEM di dalam:
2.2 Basics of Statics and Strength of Materials
2.3 Stiffness Matrix Algebra
2.4 1-D Elements
2-3 2.5 2-D Elements 1. Poros bertingkat
2.6 3-D Elements
2.7 Pre-Processing
2.8 Processing or Solution
2. Poros axial indeterminan
2.9 Post-Processing
3.0 Case Study and Project Assignments
3. Poros dengan beban torsi
3.0 Linear Static Analysis
3.1 Definition

4-5
3.2 Design Modifications B. Tuliskan source code dalam
3.3 Linear Statics Solvers
3.4 Result Visualisation and Optimisation MATLAB untuk setiap masalah
3.5 Case Study and Project Assignments
tersebut dan uraikan analisis
4.0 Design & Material Selection
4.1 Engineering Design Process prosesnya.
6 4.2 Material Selection
4.3 Mechanical and Thermophysical Properties of Materials
4.4 Case Study and Project Assignments

5.0 Simple Beam analysis

C. Buatkan model simulasi dengan
7-10
5.1 menggunakan software FEM
6.0 Software base analyses and optimisation
11-14 6.5 Hands-on and project assignments
yang anda kenal (Ansys,
PATRAN, Hyperwork, dll)
15-16 7.0 Final Exam
Relationship Between CAE, CAD, CAA & CAM/CAPP
Product/Design Cycles
Definition of Product Need; marketing information (VOC)

Conceptual Design & Evaluation; feasibility study or due diligence CAD

Design Analysis; codes & standards review, physical & analytical models

Prototype Production; testing & evaluation

CAA

Production Drawings; instruction manuals

(FEA/FEM)
CAE
Material Specification; process & equipment selection, safety review
CAM &
Pilot Production CAPP

Production

CIM
Inspection & Quality Assurance

Packaging; marketing & sales literature

Product
Product/Design Cycles

Sales & Distribution Recycling

Maintenance Support Disposal
Manufacturing
Material & Process
Experiment Engineering
Marketing
Experimental
Concurrent Engineering
Engineering
(Collaborative Automation & Optimization)
Production
Virtual Prototyping
Engineering Analysis
& Testing Design
Plant Technology Design
Technology Planning
Design Units
Design Basic Concept
Design Design Planning
Engineering Enterprise – Chain Cycles

Concept Design Manufacturing

Tools

Tools Tools

Tools
Tools

Design Analysis Prototyping Experiment

 Engineering Enterprise – Concurrent Engineering

Collaborative Engineering
Concept Design Process Infrastructure Manufacturing
MDO Technology

Design
Technology Manufacturing
Technology

Analysis Experiment
Technology Technology

Rapid Prototyping Testing

Design
Product/Design Cycles

Delivery

Ideal Simulation Zone Manufacture

Soft/Hard
Tryout

Evaluate
Cost for
Modifications
Design

Time Line
 Why focus on Design?
Manufacturing
Cost 5% Influence
In-Direct 5% to
30% Speed
20% Cost
HR Quality

15%
Material
70%

50%

Design

5%
 The Development Flow in Product Design Lifecycle

Conceptual CAE CAM Prototype

CAD
Design Technology

Experimental
SIMULATION
Testing Market

Design
Analysis
PD Evaluation
(FS)
Manufacturability
Analysis
 The Development Flow in Product Design Lifecycle

Conceptual
Design
Optimization

Conceptual CAE CAO CAM Prototype

CAD
Design Technology

Experimental
SIMULATION
Testing
Market

P-DESIGN Design P-DESIGN

EVALUATION Analysis Design Optimization, IMPROVEMENT
DOE & Sensitivity
Studies
Manufacturability
Analysis
Product/Design Cycles

DESIGN CYCLES

Chain Cycles Concurrent Engineering

Total Design Time

Effective Time + Idle Time

Product Design Engineering

PRODUCT DESIGN

Form Function Fit

Industrial Designers Engineering Analyst CAD Modelers

What is Finite Element Analysis/Method (FEA/FEM)?
◼ Finite Element Analysis/Method (FEA/FEM) consists of a Mathematical
model of a material or design (product), is stressed to analyzed for specific
results (Stress/Strain/Displacement).

◼ It is used in new product design, and existing product refinement.

◼ FEA/FEM is a way to simulate loading conditions

(Stress/Strain/Displacement) on a design and determine the design’s
response (product behavior) to those conditions.

◼ FEA and FEM both are one & the same. Term FEA is more popular in
industries while FEM at universities.

◼ In case of product or structural failure, FEA/FEM may be used to help

determine the design modifications to meet the new condition/specification.
◼ Modifying an existing product or structure is utilized to qualify the product or
structure for a new service condition.
What is Finite Element Analysis/Method (FEA/FEM)?
Radiator Bracket - Design Validation

Original Optimized
Design Design

Max. v. Mises Stress Max. Displ. Mass

What is Finite Element Analysis/Method (FEA/FEM)?
◼ All real life objects are continuous, means there is no physical gap between any
two consecutive particles.

◼ As per Material Science, any object is made up of small particles, particles of

molecules, molecules of atoms and so on, they are bonded together by force of
attraction.

◼ Solving a real life problem with continuous material approach is difficult & basic
of all numerical methods is to simplify the problem by discretizing
(discontinuation) it.

◼ So, there are 2 approaches to solve any problem;

Continuous Approach/ Discrete Approach/

Physical System F.E. Model
 What is Finite Element Analysis/Method (FEA/FEM)?

Example: Brick road from home to mailbox – measure the distance of a curved
path using yard stick

Curved path is approximated by

straight segments
Measure using a yard stick
What is Finite Element Analysis/Method (FEA/FEM)?
◼ The product/design is modeled using discrete building blocks called
elements & the entity that elements joining called nodes:

 Each element has exact equations that describe how it responds to a

certain load.
 All the calculations are made at limited number of points known as nodes.
 The “sum” of the response of all elements in the model gives the total
response of the design.
 The elements have a finite number of unknowns, hence the name finite
elements.
◼ In simple words, nodes work like atoms and with gap between filled by an
entity called as elements.
◼ Calculations are made at nodes and results are interpolated for elements.
◼ So, FEA/FEM;
 A numerical method
 Mathematical representation of actual problem
 Approximate method
What is Finite Element Analysis/Method (FEA/FEM)?

➢ Need Three levels of associativity

CAD Geometry Abstraction
Geometry Abstraction FEA
FEA CAD
Finite Element Model
Example: A frame structure

Split the members of frame into small straight pieces (1 element with 2 nodes)
and approximate the deformation on each piece
Finite Element Model

Example: A bracket

Split the surfaces of bracket into small triangular pieces (1 element with 3 nodes)
and approximate the deformation on each piece
Finite Element Model

Example: A fitting

Split the fitting into small tetrahedral pieces (1 element with 4 nodes)
and approximate the deformation on each piece
Finite Element Model
Why is FEA needed?

◼ To reduce the amount of prototype testing

 Computer simulation allows multiple “what-if” scenarios to
be tested quickly and effectively

◼ To simulate designs that are not suitable for prototype testing

 Example: Surgical implants, such as an artificial knee etc.

◼ The bottom line:

 Cost savings
 Time savings… reduce time to market!
 Create more reliable, better-quality designs
FEA in Industry

FEA does not stand on its own

An FEA optimized design must still be

validated through
PHYSICAL TESTING
FEA in Industry

Simulation Experiment

Mode I

Mixed Mode
FEA in Industry

Actual Tryout

From CAE solution

FEA in Industry
When Something Breaks ?

◼ Physical testing ◼ FEA

 Fractography  Comprehensive data
 Well instrumented
(expensive) tests  Insight into failure
 Redesign, retest mode
 Identification of
critical and non-
critical components
We keep testing and testing
and we still can’t figure out
why the darn thing breaks!!!
Making Something Better

▪ Traditional Approach ▪ FEA

▪ Scaled tests ▪ Visualization
▪ Prototype ▪ No Material Costs
▪ Redesign, retest ▪ With extreme or unrealistic
scenarios
▪ Design Cycle Time
▪ Automated Optimization
Design
▪ No. of Prototypes
▪ Testing
How to Validate/Check Accuracy of FEA Results?
• FEA is an approximate technique; level of accuracy of displayed results could be
25%, 60% or 90%.
• 10% - 15% difference in FEA & experimental results is considered as good
correlation.
• Probable reasons for more than 15% deviation-wrong boundary conditions,
material properties, presence of residual stresses, localized effects like welding, bolt
torque, experimental errors etc.

FEA ACCURACY

Computational Accuracy Correlation with Actual Testing

• Strain energy norm, residuals • Strain gauging – stress comparison
• Reaction forces & moments • Natural frequency comparison
• Convergence test • Dynamic response comparison
• Average & Unaverage stress • Temp. & pressure distribution comparison
difference
Applications Of FEA

STRUCTURAL AREAS NON STRUCTURAL AREAS

- Stress analysis; truss & frame - Heat transfer
analysis, stress concentration - Fluid flow
problems typically associated with - Distribution of electric or magnetic
holes , fillets or other changes in potential
geometry in a body
- Buckling
- Vibration
- Biomechanical Engineering; human
spine, skull, bone & hip joints,
jaw/gum tooth implants, heart, eye.
Application Of FEA
Application Of FEA

Area Typical Application

Aerospace Stress analysis of aircraft frames, wings, missile and
Engineering spacecraft components, thermal analysis of gas turbine
blades, heat exchangers; frequency analysis of engine
components, helicopter rotor blades, gearbox casing,
acoustic analysis of aircraft passenger compartments;
forced frequency analysis of aircraft and spacecraft
component, thermal analysis of rocket nozzles.
Automotive Stress analysis of crankshaft, cylinder block, connecting
Engineering rods, chassis, thermal analysis of pistons, lubrication of
big-end bearings;
Acoustic analysis of passenger compartments and exhaust
system, frequency analysis of gearbox casing and body
shell; time dependent analysis of engine components,
piston, disc brakes , exhaust, crashworthiness of chassis.
Biomedical Stress analysis of bones, hip replacements, teeth and
Engineering heart; impact analysis of skull, dynamic analysis of body
and limbs.
Application Of FEA

Civil Engineering Stress analysis of dams, retaining walls, excavations,

soil mechanics; stress waves inn rock structures

Electrical Engineering Steady state thermal analysis of integrated circuit

boards, natural frequencies of printed circuit boards

Hydraulic Engineering Analysis of water seepage and flow under dams;

aquifer analysis, natural periods of lakes and harbours,
sloshing of liquids, transient seepage and flow

Mechanical Engineering General one-, two- and three-dimensional and

axisymmetric stress analyses of components; stress
analysis of shafts, gears and pressure vessels, crack
propagation; natural frequency of components, shafts,
critical buckling loads, analysis of impact problems,
dynamic crack propagation.
Application Of FEA

Nuclear Engineering Stress analysis of reactor vessels and structures; thermal

analysis of reactor components, nuclear flux distribution,
frequency analysis of pressure vessels, time dependent
thermal analysis of reactor components; shock spectrum
analysis.

Structural Engineering Static analysis of electricity pylons, girders and bridges,

natural frequency and buckling loads of structures,
vibration analysis of multi-storey buildings, shock and
earthquake analysis of buildings and bridges.
Why To Use FEA?
A Study On FEA
A Study On FEA
FEA Terminology

Steady state
Linear analysis

Transient state
Non linear analysis

FEA

1D, 2D or 3D elements Dynamic analysis

Static analysis
FEA Equation

{f} = [K]{u}

{f} = forces working at the nodes

[K] = element stiffness matrix
{u} = displacements at the nodes
Basics of Statics & Strength of Materials

STRESS – STRAIN DIAGRAM

Basics of Statics & Strength of Materials

Assume a solution that approximates the behavior of an element

The average stress in the member is given by

The average normal strain of the member is defined as the change in length
per unit original length of the member:

Over the elastic region, the stress and strain are related by Hooke's Law,
according to the equation

where E is the modulus of elasticity of the material. Combining the equations

and simplifying, we have
Useful Equation

Note that the above equation is similar to the equation for a linear spring,

F = ku

Therefore, a centrally loaded member of uniform cross section may be

modeled as a spring with an equivalent stiffness of

L keq

u
P
P
 P Pl
d=
EA
k u = F

EeAe  1 − 1 u1   0 
− 1 1  u  =  p 
le   2   

EeAe
u2 = p
u1  0  le
u=  F = 
u 2   p p ple
u2 =
· ¸ u2 EeAe
u1 E eA e 1 ¡1
ke = `e ¡1 1
FEA Workflow

Process for FEA Analysis

1. Preprocessing
a. Import and Cad Geometry Clean up
b. Meshing.
c. Applying Material Properties.
d. Applying Loads and Boundary Conditions.

2. Solving.
Matrix Solution {F}= [K] {U}

3. Post Processing
View and compare results with Test Data if any.
FEA Workflow

Physical Problem

FEM ( generate nodes,

elements, boundary
Pre processing
conditions, material
properties, loads, data file

FEA ( generate
element matrices, compute
Solving
nodal values and
derivatives, store results

Analyze results ( contours,

curves, deformed shapes) Post processing
FEA Workflow

Physical Problem

Mathematical model

Discretization Pre processing phase

Finite element model

Finite element program Solving phase

Visualization of results Post processing phase

Building the FEA Model

CAD Model FEA Model

Building the FEA Model
Building the FEA Model
FEA Procedure

[B] is calculated based on

Discretize element type and geometry,
Create into elements [C] is calculated based upon
Geometry Material properties
Generate
stiffness matrix [ki] = [B]t[C][B]
for each element

Pre- Assemble element

stiffness matrices into
global stiffness matrix
[K]

Apply restraints {u}

Apply loads {f}

Generate system of
{f} = [K]{u}
Solver
linear equations

Solve System [K]-1 {f} = {u}

of Equations for {u}
FEA Procedure

Post- Obtain element strains

for each element {ei} = [B] {u}

Element stresses {si} = [C] {ei}

Present Results Graphically

FEA Pre-Processing

Before creating the Finite Element Model, following terms must

be considered:

- Geometry Preparation
- Material Properties
- Load Definition
- Restraint/Boundary Condition Definition
FEA Pre-Processing
Load Definition

◼ Loads applied to exterior surfaces of

the model:
 Forces on Surfaces or Edges or
Points
 Torque, Moment
 Pressure
◼ Loads acting on entire model:
 Gravity, Centrifugal force
 Thermal loads
FEA Pre-Processing

Structural Analysis Basics

Equilibrium

Compatibility

Stress-Strain
FEA Pre-Processing

Equilibrium
◼ Sum of all externally applied forces are identically zero
FEA Pre-Processing

Compatibility

◼ Relationship between nodal displacements and element strains

◼ Also the relationship between nodal forces and element stresses

{ei} = [B] {u}

FEA Pre-Processing

Stress-Strain
◼ Also known as the constitutive relationship. Defines the relationship
between stress (s) and strain (e)
100
90
80
70
60 s= E e
s (ksi)
Stress/Strain
50
for Steel
40
Valid over the
30
elastic range
20
10
0
0 0,5 1

e (%)
The general constitutive relationship [C] is a 6 by 6 matrix
{s} = [C][e}
FEA Pre-Processing
Restraint/Boundary Conditions

• Boundary conditions in FEA

represent how the physical part is
attached to the rest of its “universe”

• It is not always practical or necessary to

analyze an entire system

• By use of boundary conditions, a system

level analysis can be reduced to a
component level analysis
FEA Pre-Processing
Restraint/Boundary Conditions

◼ All objects have SIX RIGID BODY MODES

◼ A rigid body mode (RBM) is a motion that is not accompanied by any
deformation

3 rigid body translations

and
3 rigid body rotations
FEA Pre-Processing
Restraint/Boundary Conditions

Cantilevered Guided Support

All translations
Only one translation is permitted
and rotations are fixed
FEA Pre-Processing
Restraint/Boundary Conditions

Spline Joint Pin or Hinged Joint

All rotations are fixed, All translations are fixed

only axial translation is permitted Only one rotation is permitted
FEA Pre-Processing
Restraint/Boundary Conditions

Ball and Socket Roller Support

All translations are fixed, Vertical Translation is fixed

All rotations are permitted Rotation about vertical axis
Is permitted
FEA Pre-Processing
Restraint/Boundary Conditions
LOAD = 1500N

TANK
FIXED FIXED
CONSTRAINT CONSTRAINT
FEA Pre-Processing

Mesh, Nodes, Elements, …

◼ MESH – Approximate representation of the CAD
geometry using Tetrahedra or Triangles

◼ ELEMENTS – Tetrahedra or Triangles in the Mesh

◼ NODES - Points at which different elements are

jointed together; nodes are the locations where
values of unknowns (usually displacements) are to
be approximated
FEA Pre-Processing
Meshing

◼ A finite element model is a

discretized representation of a
physical object

◼ The FE model is composed of

nodes and elements
FEA Pre-Processing
Meshing

◼ Meshing is the process used to “fill” the solid model with nodes and
elements, i.e, to create the FEA model.

meshing

Solid model FEA model

FEA Pre-Processing
Element/Node Definition

◼ Stresses and strains are

calculated within each
element
◼ Forces and displacements
are calculated at nodes
◼ Interactions between
elements are via the nodes
◼ Elements can be divided into
two main categories
 Continuum (solid, plane2d)
 Structural (beams, shells)
FEA Pre-Processing
Element/Node Definition
FEA Pre-Processing
Element/Node Definition
FEA Pre-Processing

Element/Node Definition

Node (UX, UY,UZ,RX,RZ,RZ) for Structural Element

Node (Temp for Thermal Element)

Element
FEA Pre-Processing

Direct Displacement Method Used in FEA

◼ Displacements are treated as unknowns
◼ Each node can have up to six displacement degrees of freedom
(DOF), ux, uy, uz, qx, qy, qz
 Depending on context, not all DOF’s will be present
◼ Continuum elements in 2-d has only ux and uy
◼ Structural elements in 2-d has ux, uy, and qz
◼ Continuum elements in 3-d has only ux, uy and uz
◼ Structural elements in 3-d has all six
◼ All active DOF’s have a corresponding force or moment
 FEA Pre-Processing
Element Types
Elements

1-D 2-D 3-D

Element Shape – Line Element Shape – Quad, Tria Element Shape – Tetra, Hexa

Element Type – Rod, Bar, Beam, Element Type – Thin Shell, Plate, Element Type – Solid
Truss, Frame, Pipe, Spring, Membrane, Plane stress, Plane
Damper, Axi-symmetric shell etc. Strain, Axi-symmetric solid etc. Practical Applications
Casting parts/components,
Practical Applications Practical Applications i.e. Transmission casing, Engine
Long shafts, Beams, Pin joint, Sheet metal parts, Plastic block, Crankshaft etc.
Connection elements etc. components etc.
Additional Info – All dimension
Additional Info – One of the Additional Info – Two of the are comparable.
dimension is very large in dimensions are very large in
comparison to rest of the two. comparison to third one.
FEA Pre-Processing
Element Types

3D

2D

1D
FEA Pre-Processing
Element Types
1D i. Spring
1 Dimensi
ii. Bar
nod iii. Truss
unsur
iv. Beam
v. Frame

y
2D
2 Dimensi

Sheet Metal & Plastic Parts

3D
3 Dimensi
z

x,y

Casting Parts/Process
FEA Pre-Processing
Element Types
1D Model 2D Model 3D Model

Quad Hexa

Tria Tetra
FEA Pre-Processing
Element/Node Definition
FEA Pre-Processing
Element/Node Definition
 FEA Pre-Processing
Element Types – 1D

Split the members of frame into small straight pieces (1 element with 2 nodes)
and approximate the deformation on each piece
FEA Pre-Processing
Element Types – 1D
FEA Pre-Processing
Element Types – 1D
FEA Pre-Processing
Element Types – 2D

Split the surfaces of bracket into small triangular pieces (1 element with 3 nodes)
and approximate the deformation on each piece
FEA Pre-Processing
Element Types – 2D; Midsurfacing

▪ For many FE analyses, parts are represented by shell elements

• Thickness is assigned mathematically, rather than geometrically
• Mesh is usually placed on the midplane of the part

▪ CAD geometry usually comes as a solid part

▪ Midsurfacing creates a layer of surfaces on the midplane which can be

directly meshed
FEA Pre-Processing
Element Types – 2D
FEA Pre-Processing
Element Types – 3D

Split the fitting into small tetrahedral pieces (1 element with 4 nodes)
and approximate the deformation on each piece
FEA Pre-Processing
Element Types – 3D
▪ Basic process of using solid map: volume is:

1. Create solid geometry 2. Split the solid geometry into

mappable regions

3. Use solid map to create hex mesh on each solid entity

FEA Pre-Processing
Element Types – 3D
Fixed load

Stress Plots

Displacements

Pressure load
FEA Pre-Processing
How To Decide Element Types

Elements Type Selection

Geometry Size & Shape Type of Analysis Time Allotted for Project
1-D

Linear Analysis If time constraint:-

Crash & Non-Linear Analysis i. Automatic or batch meshing tools recommended
Structural & Fatigue Analysis to be used
Mould Flow Analysis ii. For 3-D meshing tetras preferred over hexas
2-D Dynamic Analysis iii. If assembly components, only critical parts are
Etc. meshed.

If no time constraint:-
i. Mesh flow lines and good mesh quality is
recommended.

3-D
 FEA Pre-Processing
Can Solve Same Problem Using 1-D, 2-D & 3-D Elements?
For example, consider cantilever beam, dimension 250 x 20 x 5mm subjected to 35N force:

Is it not possible to use 3-D elements for beam structure (1-D) and sheet metal
parts (2-D) and 2-D shell elements for representing casting parts.
FEA Pre-Processing
How to Start Meshing?

1. Spend sufficient time in studying the geometry

2. Time estimation

3. Geometry check
- Free edges, Scar lines, Duplicate surfaces, Small
fillets, Small holes, Beads, Intersection of parts
(assembly of components)

4. Symmetry check

5. Selection of type of elements

Meshing
8 Cylinder Engine Block
Meshing
Cylinder Head
Meshing

Side Impact Model

Meshing

Model Setup and Frontal Crash Analysis

Meshing
Truck Frame Model
Meshing
Transmission Housing
FEA Pre-Processing
Mesh Generation
Refers to the generation of nodal coordinates and elements. It also includes the
automatic numbering of nodes and elements based on a minimal amount of
user – supplied data. Automatic mesh generation reduces errors and saves a
great deal of user time and therefore FEA cost.

Before the existence of pre processor, finite elements meshes were generated
manually. Manual meshing is inefficient, error prone and meshing data can
grow rapidly and become confusing for complex 3D object.

With wide spread use of computer graphics and CAD technology, mesh
generation has been a target of automation. There is a wide variety of
algorithm, schemes and methods for mesh generation. They have various
levels of automation and different user – input requirements.

A fully automatic mesh generation is taken to mean a method in which only the
shape (both geometry and topology) of the object to be meshed and the mesh
attributes (mesh density, element type, boundary conditions, loads etc.) are
required as input. Any other method that may require additional input such as
Subdividing the object into subdomains or regions is a semi – automatic one.
FEA Pre-Processing
Mesh Requirements
1. Nodal locations – Nodes must lie inside or on the boundaries of the
geometric model to be meshed. Nodes that are very close to the
boundaries must be pulled to lie on them to accurately mesh the model.
2. Element type and shape – It is desirable if various elements can be
generated to provide users with the required flexibility.
3. Mesh gradation – Usually refers to mesh grading and density control. Most
often, objects on which FEA is performed may have holes or sharp
corners. It is usually required that mesh density (number of nodes and
elements) is increased around these regions to capture the rapid change
(eg. stress variation) of the field variable.
4. Mesh conversion – It may be desirable to convert a mesh of a given type
of element to another mesh of a different element type.
5. Element aspect ratio – It is important to keep the aspect ration of any
element close to 1, that is all sides of an element are equal in length
6. Mesh geometry and topology – Mesh geometry refers to the coordinates of
nodal points and the connectivity information of elements. Mesh topology
refers to the mesh orientation relative to object topology. Object topology
always determines the mesh topology.
 FEA Pre-Processing
Mesh Requirements
 FEA Pre-Processing
Mesh Requirements
Suppressing Adding Removing Adding Replacing
edges edges fixed points fixed points fixed points
Before
After
FEA Pre-Processing
Mesh Requirements
FEA Pre-Processing
Mesh Requirements
FEA Pre-Processing
Mesh Transition Techniques
 FEA Post Processing
Using Stress Results to Validate Design
◼ Stresses at a point are defined by 6 quantities – 3 normal
stress and 3 shear stresses – depend on orientation of
coordinate system

◼ Von Mises Stress =

VON is independent of coordinate system

◼ Factor of Safety =

◼ Principal Stresses – 3 normal stresses specified in a

special coordinate system for which shear stresses are
zero
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Basic Failure Theories

We can calculate the distribution of the stress components σx, σy and τxy as well
as the principal stresses σ1 and σ2 within the material. But how would we decide
whether or not the solid part we are analyzing will permanently deform or fail
under the applied loading?

So we introduce a Factor of Safety (F.S.), which is defined as

where Pmax is the load that can cause failure.

But how do we apply the knowledge of stress distributions in a material to
predict failure? Let us begin by reviewing how the principal stresses and
maximum shear stresses are computed.
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Basic Failure Theories

The in-plane principal stresses σxx, σyy and τxy at a point are determined from the
values of that point using the equation:

The maximum in-plane shear stress at the point is determined from the relationship:

There are a number of failure criteria, including the maximum-normal-stress theory,

the maximum-shear-stress theory, and the distortion-energy theory. For design
purposes, the Von Mises stress is calculated according to the equation:
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Basic Failure Theories

A safe design is one that keeps the Von Mises stresses in the material below
the yield strength of the material. The relationship among the Von Mises
stress, the yield strength, and the factor of safety is:

where Sy is the yield strength of the material, obtained from a tension test.
1-D Meshing
1D-Meshing
Example:

1:
Element 1:

Element 2:
Assignment 1 (5%)
1
2.

2.
 Assignment 2 (10%)
Obtain the nodal displacements and the element internal forces, given
that A= 1 in² and E=30E6psi for all members. All results must be present &
compare through Analytical & Simulation approach.

Figure 3. A three-element bar structure

Example
4

4
Non – Linear Analysis

3 types of Non Linearities

geometrical
physical
contact
Non – Linear Analysis
Physical - Material

Geometrical
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