Fundamentals of FEA analysis

INTRODUCTION

Jan, 2015

Created by: Le Hoai Thanh (Altair)

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History of FEA

1906 – Cilvil Engineering Application, Structural analysed by 1-D beam

1909 – Variational Method
1915 – Galerkin: Weighted residuals
1940s – Courant, Prager: Mathematical foundation for present form of FEA
1950s – Argyris, Kelsey: Direct continuum elements, aerospace industrial engineers formulated
stiffness equation: 100 dof problem was supposed to be very large at that time.
1960 – Clough coined the name FINITE ELEMENT METHOD
Late 1960s – Mechanical industry recoginized FEM as useful tool for solve real life problems. Many of
the present popular FEA software were launched in the market
1980s – Graphical & computational development
1990s – Emergence of low cost, powerful PC workstation and FEA adopted by mid and small scale
industries.

Year 1961 1966 1971 1976 1986 2006

Papers 10 134 844 7000 20,000 infinite

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FEA analysis

Methods to solve any engineering problems

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 Expense 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

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FEA = Finite Element Analysis

• Finite: FEM reduce the dof from Infinite to Finite with the help of discretization 
Meshing (node and element)
• Element: All the calculations are made at limited number of points known as nodes.
Entity joining nodes a nd forming a specific shape such as quad/trias etc. is known as
element. To get displacement any where in between the calculation points interpolation
function (shape of element) is used.
• Method: there are 3 methods to solve engineering problems. FEM belongs to
numerical method category.
FEM terminology  Academy
FEA terminology  Industries

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Brief introduction to difference Numerical Method

1. FEM(Finite Element Method)

• The most popular numerical method
• Application: Linear, Nonlinear, Buckling, Thermal, Dynamic & Fatigue analysis. FEM will be
discussed in detail at later stage

2. BEM (Boundary Element Method)

• Very powerful and efficient technique to solve acoustics or NVH problems.
• Requires nodes and elements but as the name suggest it considers only outer boundary of the
domain  reduces dimensionality of the problem by a degree of one & thus solving it faster.

3. FVM (Finite Volume Method)

• Unit volume is considered in Finite Volume Method (similar to element in finite element analysis).
• Variable properties at nodes are pressure, velocity, area, mass etc. It is based on Navier - Stokes
equations (Mass, Momentum and Energy conservation equilibrium equations).

4. FDM (Finite Differential Method)

• In general Finite Difference Method is described as a way to solve differential equation
• Uses Taylor's seriez to convert differential equation to algebraic equation

Is it possible to use all of the methods listed above (FEA, BEA, FVM, FDM) to solve the same problem (for
example, a cantilever problem)?
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Design process
CONVENTIONAL DESIGN PROCESS CAE ASSISTED DESIGN PROCESS

REQUIREMENT REQUIREMENT

CONCEPT CONCEPT

DESIGN DESIGN

DESIGN DEVELOPMENT (CAD) DESIGN DEVELOPMENT (CAD)

PHY-PROTO VIRTUAL-PROTO

CAE
PHY-TEST VIRTUAL-TEST

DESIGN VALIDATION RESULT INTERPRETATION

MANUFACTURABILITY STUDIES MANUFACTURING SIMULATION

MANUFACTURING MANUFACTURING
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The CAE Process?

CAE

Pre Processing Solving Post Processing

Virtual Prototype
Virtual Test

Result Interpretation

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Advantages of CAE

• Visualization ↑
• Design cycle the ↓
• No. of prototypes ↓
• Testing ↓

• Optimum design

Visualization of results: For simple geometries such as simply supported beam or cantilever beam it is easy to
visualize point of maximum stress and displacement. But in real life for parts or assemblies with complex
geometrical shapes, made up of different materials with many discontinuities subjected to flexible constraints,
complex loading varying wrt the and pointof application, further complicated by residual stresses and joints like
spot and arc welds etc., itis not easy to predict failure location

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Is FEA a replacement for Costly & Time Consuming Testing

 FEA has minimized testing requirement but it will be wrong to assure

that it has or will replace testing

 FEA and Testing are not rivals but friends.

A CAE engineer depends on testing for the following reasons

1) Input data for CAE (Data acquisition)

2) Validation of CAE results

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3. Types of analysis

The term CAE (Computer Aided Engineering) includes following types of

analysis

1. Linear static analysis

2. Non Linear analysis
3. Dynamic analysis
4. Buckling analysis
5. Thermal analysis
6. Fatigue analysis
7. Optimization
8. CFD analysis
9. Crash analysis
10. NVH analysis

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Linear static analysis

• In mechanics 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:
• Small deflections
• Small rotations
• Linear Elastic Material
• Constant BC

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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. 12
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Non Linear Analysis

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Dynamic Analysis

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Thermal Analysis

Practical applications: Engine, radiator, exhaust system, heat exchangers, power plants, satellite design etc.
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Computational Fluid Dynamics (CFD)

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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).

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Fatigue Analysis

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Optimization

• Nature as structural engineer

• Stem, Bamboo, insect trachea, bee-hive

• Nature as a CFD solver

• Birds, fishes

• Nature as a drag reducer

• Penguin body

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Optimization

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Optimization 1 - TOPOLOGY

Before

5 20
Repetitions Repetitions Optimization
Symmet

Results
No

ry
Symmet
ry

After
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Optimization 2 - TOPOGRAPHY

Pressure Tank – Symmetry Control

• Thin walled tank filled with fluid to be optimized for stiffness
• Three orthogonal planes of symmetry are defined

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Crash Analysis

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Noise Vibration and Harshness, NVH

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Common Mistake and Errors

CAE engineer mistakes

1) Submission of a job without the proper checking (should be cross checked by ideally 2
CAE engineers)
2) Import / Export errors
3) Experienced engineers are the best guides and teachers for newcomers and less
experienced colleagues
4) Meshing is considered as low level work, post graduates and PhDs are reluctant to
spend time on meshing
5) CAE engineers are reluctant to visit the shop floor, testing department, or field to study
the manufacturing, functioning, and failures of the components
6) Providing basic training related to data acquisition and testing
7) Unnecessary emphasis on modeling the minute details without giving due consideration
to available time, hardware, and software capabilities
8) While suggesting the modifications, no consideration for the manufacturing constraints
and the cost effectiveness
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