Harness the Power

of Finite Element Analysis

Published by FEA Academy
www.fea-academy.com
Contact the author at: [email protected]

© 2024 Dominique Madier. All rights reserved.

Copyright registered with the Canadian Intellectual Property Office at Innovation, Science and
Economic Development Canada. The Certificate of Registration has been issued pursuant to section
49 and 53 of the Copyright Act under registration number 1209463.

Legal deposit
Library and Archives Canada, 2024

Editing: Valerie Paterson, Prescott, ON, Canada and Saro Chichmanian, Montreal, QC, Canada
Layout: Alain Carpentier, Ecographie Communication and Design, Clermont-Ferrand, France

ISBN Hardcover: 978-1-9990475-4-2

ISBN eBook: 978-1-9990475-5-9

Trademarks
Commercial software names, company names, and trademarks contained in this book are used only
for identification and explanation without intent to infringe on their property rights.

Legal Disclaimer and Exclusion of Liability

The author reserves the right to make changes to information contained in this book, without prior
notice. The author assumes no liability or responsibility to any person or company for direct or indirect
damage resulting from the use of any information contained herein.

Intellectual Property Rights and Artificial Intelligence Usage

Any reproduction of any extract of this book by any means whatsoever, including photocopying,
microfilm, or scanning, is strictly prohibited without the written permission of the publisher.
Unauthorized reproduction of this publication will be considered a copyright infringement. FEA
Academy prohibits the entry of this book into any form of Artificial Intelligence (AI) tool. Creating
derivatives of FEA Academy content using AI is also prohibited without express written permission
from Dominique Madier. In the case of such use, further legal action will be considered.
 HARNESS THE POWER OF FINITE ELEMENT ANALYSIS

TABLE OF CONTENTS

FOREWORD BY TONY ABBEY FRAES ............................................................................. 1

PREFACE BY THE AUTHOR ............................................................................................ 3

TOP 10 FAQS RELATED TO MANAGING AN FEA TEAM ........................................... 7

GUIDE 1. EXPLORING FINITE ELEMENT ANALYSIS .................................................. 9

1. Introduction ................................................................................................................9
2. Understanding Finite Element Analysis (FEA).........................................................9
The Equations that Govern Physics ........................................................................................ 10
Methods for Solving Engineering Problems ......................................................................... 11
What is Finite Element Analysis (FEA)? ................................................................................. 13
The FEA Concept: Divide and Conquer ................................................................................... 13
From the Continuous Problem to the Discretized Solution ............................................. 17
FEA Application Across Industries ........................................................................................... 19
Using FEA at Every Stage of Product Design ....................................................................... 22
3. Importance of FEA in Engineering and Design ..................................................... 23
4. Some FEA Statistics and Facts ............................................................................... 26
Growth of the Finite Element Analysis Market ................................................................... 26
Time and Cost Savings ................................................................................................................ 27
Project and Product Development Efficiency ...................................................................... 29
Impact of Poorly Managed FEA Projects ............................................................................... 30
Demand for FEA Professionals ................................................................................................ 31
5. Conclusion ............................................................................................................... 32
6. Case Studies from the Field ................................................................................... 33

Table of Contents
 HARNESS THE POWER OF FINITE ELEMENT ANALYSIS

GUIDE 2. BUILDING AND MANAGING AN EFFECTIVE FEA TEAM .............................. 35

1. Introduction ............................................................................................................. 35
2. Structuring Your FEA Team .................................................................................... 36
Key Roles and Responsibilities ................................................................................................. 36
Building a Balanced Team .......................................................................................................... 39
3. Skills and Qualifications of an FEA Team .............................................................. 41
Technical Skills and Software Proficiency ............................................................................. 41
Continuous Learning and Professional Development ....................................................... 42
4. Managing FEA Projects........................................................................................... 45
5. Successful Technical Projects Through Project Management ............................ 46
Clarification of Objectives and Scope ..................................................................................... 46
Efficient Resource Allocation .................................................................................................... 47
Comprehensive Risk Management ......................................................................................... 47
Meticulous Timeline Management .......................................................................................... 47
Budgeting and Cost Control....................................................................................................... 48
Quality Assurance ......................................................................................................................... 49
Regulatory and Standards Compliance .................................................................................. 52
Examples of Quality Standards in Finite Element Analysis ............................................. 52
Integration Management ........................................................................................................... 53
Adaptability to Change ................................................................................................................ 54
Documentation and Knowledge Transfer ............................................................................. 54
Incorporating Innovation and Continuous Improvement ................................................. 55
Data Management ....................................................................................................................... 55
Software Proficiency ................................................................................................................... 55
6. Collaboration and Communication ........................................................................ 56
The Significance of Communication in FEA Projects ......................................................... 56
Communication of Results......................................................................................................... 57
Impact of Collaboration on FEA Project Outcomes ............................................................ 58
Tools and Techniques for Effective Engagement ............................................................... 60
7. Common Challenges in FEA Projects ..................................................................... 63
8. Conclusion ............................................................................................................... 66
9. Case Studies from the Field ................................................................................... 66

Table of Contents
 HARNESS THE POWER OF FINITE ELEMENT ANALYSIS

GUIDE 3. ENSURING ACCURACY AND QUALITY IN FINITE ELEMENT ANALYSIS............ 68

1. Introduction ............................................................................................................. 68
2. The Significance of Accuracy and Quality in FEA Results .................................... 69
3. Challenges and Pitfalls of Maintaining High Standards in FEA .......................... 73
4. Strategies for Quality Assurance and Control in FEA .......................................... 77
5. Verification and Validation (V&V) Processes in FEA ............................................ 81
Understanding V&V ..................................................................................................................... 81
Importance of V&V ....................................................................................................................... 81
Verification Process ..................................................................................................................... 82
Validation Process ........................................................................................................................ 84
Statistical Methods in V&V ........................................................................................................ 85
Documentation and Reporting of V&V ................................................................................... 87
Challenges in Validation .............................................................................................................. 87
Best Practices in V&V .................................................................................................................. 88
6. Documentation and Reporting in FEA Projects .................................................... 90
Role and Importance of Documentation and Reporting in FEA...................................... 90
Reporting Project Progress in FEA .......................................................................................... 93
7. Conclusion ............................................................................................................... 96
The Critical Role of Accuracy and Quality in FEA ................................................................. 96
Challenges in FEA and Their Impact ........................................................................................ 96
Strategies for Effective Management and Quality Assurance ........................................ 97
The Importance of a Proactive and Integrated Approach ................................................ 97
Bridging the Gap between Theory and Practice .................................................................. 97
8. Case Studies from the Field ................................................................................... 98

GUIDE 4. TOOLS, SOFTWARE, AND RESOURCES FOR FEA TEAMS ......................... 100
1. Introduction ........................................................................................................... 100
2. Essential Tools for an Effective FEA Team ......................................................... 100
Leading FEA Solvers ................................................................................................................. 101
Pre-Processing Software ........................................................................................................ 103
CAD Integration .......................................................................................................................... 105

Table of Contents
 HARNESS THE POWER OF FINITE ELEMENT ANALYSIS

Data Visualization and Reporting Software ...................................................................... 106

Advanced Computational Hardware .................................................................................... 106
Cloud Computing Platforms ................................................................................................... 106
Examples of Cloud-Based FEA Solutions ........................................................................... 107
Material Database ..................................................................................................................... 108
Custom Scripting and Automation Tools ............................................................................ 114
Training and Educational Resources .................................................................................... 115
3. Typical High-Performance Computing (HPC) for Solving Complex Problems . 117
Processor (CPU).......................................................................................................................... 117
Graphics Processing Unit (GPU) ............................................................................................ 118
Memory (RAM) ........................................................................................................................... 118
Storage.......................................................................................................................................... 118
Network ........................................................................................................................................ 119
Software ....................................................................................................................................... 119
Scalability ..................................................................................................................................... 119
Reliability and Redundancy .................................................................................................... 119
Why Invest in HPC? ................................................................................................................... 120
Estimation of Cost Reduction Using HPC ........................................................................... 121
4. Cloud-based vs. Traditional On-premises FEA Tools......................................... 124
Understanding On-premises FEA Tools ............................................................................. 124
Exploring Cloud-based FEA Tools ......................................................................................... 125
Cost-Benefit Analysis............................................................................................................... 126
Comparing Costs for on-Premises Vs. Cloud-Based Solutions ................................... 128
Security Concerns ...................................................................................................................... 129
Future Trends and Developments ........................................................................................ 132
5. Comparing FEA Software: Capabilities and Cost ................................................ 134
Cost Considerations .................................................................................................................. 134
User Support and Community ............................................................................................... 136
6. Open-source FEA Tools for Professional Use ..................................................... 138
Advantages of Open-source FEA Tools .............................................................................. 138
Popular Open-source FEA Tools ........................................................................................... 140
Limitations and Challenges..................................................................................................... 141
Overcoming Challenges ........................................................................................................... 142
The Future of Open-source FEA Tools ................................................................................ 144

Table of Contents
 HARNESS THE POWER OF FINITE ELEMENT ANALYSIS

7. Selecting the Right FEA Software for Industry Applications ............................ 146
Understanding Industry-Specific Needs ............................................................................ 146
Evaluating Software Features ............................................................................................... 148
The Best FEA Software for Specific Industries: ................................................................ 149
Cost and Licensing Models ..................................................................................................... 163
Support, Training, and Community ....................................................................................... 167
Compliance and Standards ..................................................................................................... 168
Trials and Testing ...................................................................................................................... 169
Looking to the Future ............................................................................................................... 170
8. Impact of FEA Software on Simulation Accuracy and Speed ............................ 173
Understanding Simulation Accuracy in FEA ...................................................................... 173
Factors Affecting Simulation Speed..................................................................................... 174
Balancing Accuracy and Speed .............................................................................................. 178
Best Practices for Maximizing Accuracy and Speed ....................................................... 179
9. The Importance of Finite Element Model (FEM) Guidelines.............................. 181
10. Simulation Process and Data Management (SPDM) Solutions ......................... 183
What is SPDM? ........................................................................................................................... 183
Advantages .................................................................................................................................. 183
Challenges.................................................................................................................................... 183
Application of SPDM ................................................................................................................. 184
SPDM Implementation............................................................................................................. 184
SPDM’s Suitability ..................................................................................................................... 184
The Future of SPDM ................................................................................................................. 185
Case Study ................................................................................................................................... 185
SPDM Solutions ......................................................................................................................... 188
11. Conclusion: Navigating the World of FEA Software for Optimal Engineering
Solutions ........................................................................................................................ 190
12. Case Studies from the Field ................................................................................. 191

GUIDE 5. PROFESSIONAL DEVELOPMENT AND SKILL BUILDING IN FEA TEAMS........ 194

1. Introduction ........................................................................................................... 194
2. How to Become an FEA Specialist ....................................................................... 195

Table of Contents
 HARNESS THE POWER OF FINITE ELEMENT ANALYSIS

Overview ...................................................................................................................................... 195

What Does an FE Analyst Need to Learn? ......................................................................... 196
Guidelines for FEA Learning ................................................................................................... 198
Wheel of Structural FEA Competencies .............................................................................. 202
Conclusion .................................................................................................................................... 203
3. Understanding Professional Development in FEA Teams ................................. 205
Definition and Scope ................................................................................................................. 205
Key Components ........................................................................................................................ 206
Relevance to the Evolving Landscape ................................................................................. 207
4. The Importance of Skill Building for FEA Professionals .................................... 209
Enhancing Analytical Capabilities ......................................................................................... 209
Adapting to FEA Industry Changes....................................................................................... 210
Fulfilling Industry and Client Expectations ......................................................................... 211
Skill Development Challenges ............................................................................................... 212
Strategies for Effective Skill Building .................................................................................. 213
5. Keeping Pace with Industry Developments ........................................................ 216
Embracing Technological Advancements .......................................................................... 216
Leveraging Collaborative Networks ..................................................................................... 217
Encouraging a Culture of Innovation ................................................................................... 218
Evaluating and Integrating Feedback .................................................................................. 219
6. Best Practices for Creating a Learning Environment ......................................... 223
Establishing a Culture of Growth .......................................................................................... 223
Implementing Learning Programs ........................................................................................ 225
Online Learning Platforms ...................................................................................................... 231
Online Forums and Communities ......................................................................................... 232
Reputable Conferences and Seminars with a Significant Focus on FEA .................. 233
Academic Partnerships and Collaborations: ...................................................................... 235
7. Conducting Skills Gap Analyses ........................................................................... 238
Frequency of Skills Gap Analyses ......................................................................................... 238
Methodologies for Conducting Skills Gap Analyses ........................................................ 238
Application of Skills Gap Analyses in FEA Teams ............................................................ 239
8. Impact of Professional Certifications .................................................................. 242
Enhancing Theoretical Knowledge and Practical Skills .................................................. 242

Table of Contents
 HARNESS THE POWER OF FINITE ELEMENT ANALYSIS

Standardization of Skills and Practices ............................................................................... 242

Keeping Up with Industry Developments .......................................................................... 242
Enhanced Credibility and Client Confidence ...................................................................... 243
Encouraging a Culture of Continuous Improvement ....................................................... 243
Impact on Complex and Specialized Projects .................................................................... 243
Example of Professional Certification in FEA .................................................................... 244
9. Measuring Return on Investment (ROI) of Development Programs ................ 247
Quantifying Benefits and Long-Term Impact on Team Performance ....................... 247
10. Conclusion ............................................................................................................. 253
11. Case Studies from the Field ................................................................................. 254

THE PIVOTAL ROLE OF FEA IN PRODUCT DEVELOPMENT ..................................... 259

The Role of Management in FEA .......................................................................................... 260
Integrating FEA in Product Development........................................................................... 260
Challenges and Opportunities ................................................................................................ 261
Looking Ahead: The Future of FEA in Engineering ........................................................... 261
Final Reflections......................................................................................................................... 261

LIST OF ACRONYMS................................................................................................. 263

REFERENCES.......................................................................................................... 264

Table of Contents