Unit - 2

Finite Element Method (FEM) /

Finite Element Analysis (FEA)

1
 PRE-REQUISITE

Algebra of matrix.

Numerical method techniques.

Advance mechanics of solids

2
INTRODUCTION: FEM/ FEA
The Finite Element Method (FEM) is a numerical method
for solving problems of engineering and mathematical
physics.

Useful for problems with complicated geometries,

loading, and material properties where analytical
solutions cannot be obtained.
 FEM
FEM: Method for numerical solutions of field problems.

Description

• FEM cuts a structure into several elements (pieces of the

structure).

• Then reconnects elements at “nodes” as if nodes were

pins or drops of glue that hold elements together.

• This process results in a set of simultaneous algebraic

equations.

Number of degrees-of-freedom (DOF)

Continuum: Infinite
 The Purpose of FEA
(Analytical vs FEM)
Analytical Solution FEM
• Stress analysis for trusses, • Design geometry is a lot more
beams, and other simple complex; and the accuracy
structures are carried out based requirement is a lot higher. We
on dramatic simplification and need
idealization: □ To understand the
□ mass concentrated at the center behaviors of a complex object
physical
of gravity (strength, heat transfer capability,
□ beam simplified as a line segment fluid flow, etc.)
(same cross-section) □ To predict the performance and
• Design is based on the behavior of the design; to
calculate the safety margin; and
calculation results of the to identify the weakness of the
idealized structure & a design accurately
safety
largefactor (1.5-3) given
□ To identify the optimal design
by experience. with confidence
 Fundamental Concepts
• Many engineering phenomena can be expressed by
“governing equations” and “boundary conditions”.
• It is very difficult to make the algebraic equations for
the entire domain
– Divide the domain into a number of small, simple elements

– Afield quantity is interpolated by a polynomial

over an element

– Adjacent elements share the DOF at connecting nodes

• FEM uses the concept of piecewise polynomial interpolation.

• By connectingelements together, the field quantity

becomes interpolated over the entire structure in piecewise
fashion.

• A set of simultaneous algebraic equations at nodes.

 Brief History

• 1943:Richard Courant, a mathematician

described a piecewise polynomial solution
for the torsion problem of a shaft of arbitrary
cross section, Even holes. The early ideas of
FEA date back to a 1922 book by Hurwitz
and Courant.
• His work was not noticed by engineers and
the procedure was impractical at the time due
to the lack of digital computers.

1888-1972: b in Lublintz Germany

Student of Hilbert and Minkowski in Gottingen Germany
Ph.D in 1910 under Hilbert’s supervision.

1934: moved to New York University, founded the Courant Institute

 Brief History Cont….

• In the 1950s: Work in the aircraft industry

introduced FE to practicing engineers.

• A classic paper described FE work that

was prompted by a need to analyze delta
wings, which are too short for beam theory to
be reliable.

• 1960: The name "finite element" was coined

by structural engineer Ray Clough of the
University of California.
Professor emeritus of Structural Engineering at UC Berkley
Ph.D from MIT
Well known earthquake engineer
 Brief History Cont….

• By 1963 the mathematical validity of FE was recognized and

the method was expanded from its structural beginnings to include
heat transfer, groundwater flow, magnetic fields, and other areas.
• The first book on the FEM by Zienkiewicz and Chung was
published in 1967.
• Large general-purpose FE software began to appear in the 1970s.
• By the late 1980s the software was available on
microcomputers, complete with color graphics and pre- and
post-processors.
• By the mid 1990s roughly 40,000 papers and books about
FE and its applications had been published.
• Till date most commercial FEM software packages are
available and this subject is matured enough to solve any
complex problems. (Abaqus, Adina, Ansys, etc.)
 Advantages of the FEM

• Can readily handle very complex geometry:

□ The heart and power of the FEM

• Can handle a wide variety of engineering problems

□ Solid mechanics
□ Dynamics
□ Heat problems
□ Fluids
□ Electrostatic problems

• Can handle complex restraints

□ Indeterminate structures can be solved.

• Can handle complex loading

□ Nodal load (point loads)
□ Element load (pressure, thermal, inertial
forces)
 Disadvantages of the FEM

• A general closed-form solution, which would permit oneto

examine system response to changes in various parameters, is
not produced.

• The FEMobtains only "approximate" solutions.

• The FEM has "inherent" errors.

• Mistakes by users can be fatal.

Finite Element Analysis
Discretizations
Model body dividing it into an
equivalent
by system of many smaller
bodies or units (finite
interconnected at elements) points
two or more elements (nodestoor nodal
common
points) and/or boundary lines and/or
surfaces.
Features

• Obtain a set of algebraic equations to solve for

unknown (first) nodal quantity (displacement).
• Secondary quantities (stresses and strains) are
expressed in terms of nodal values of primary
quantity.
A General Procedure For
Finite Element Analysis
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 To use the FEA packages properly, the user
must know the following points clearly:
• Which element is used for solving the problem in hand.
• How to discritise to get good result.
• How to introduce boundary conditions properly.
• How the element properties are developed and what are their
limitations.
• How the displays are developed in pre and post processor to
understand their limitations.
• To understand the difficulties involved in the development of FEA
programs and hence the need for checking the commercially
packages with the results of standard cases.
Unless user has the background of FEA, He may produce worst
results and may go with overconfidence.

Hence it is necessary that the user of FEA package should have

sound knowledge of FEA.
Responsibility of the user
Errors Inherent in FEM Formulation
Errors Inherent in Computing
 Mistakes by Users

• Elements are of the wrong type e.g) Shell elements

are used where solid elements are needed
• Distorted elements

• Supports are insufficient to prevent all

rigid-body motions
• Inconsistent units (e.g. E=200 GPa, Force = 100 lbs)

• Too large stiffness differences Numerical

difficulties
 TYPES OF FINITE ELEMENT ANALYSIS or
FINITE ELEMENT ANALYSIS CAPABILITIES or
FINITE ELEMENT ANALYSIS ENGINEERING

Linear Static Stress Analysis

□ Factor of Safety Calculation
□ Part & Assembly Stress Analysis
□ Deflection Calculations
□ Correlation to Measurements of Deflections
and Strains
□ Contact Stress Computation
□ Super-position of Thermal Stresses
□ Stiffness Calculations to achieve stated Targets
• Frequency & Buckling Analysis

□ Computation of Frequencies & Mode Shapes

□ Modal Assurance Criteria (MAC)
□ Correlation to Measured data
□ Buckling Calculations for axially loaded
members
□ Critical Speed Calculations
□ Campbell Diagram for Rotor-dynamics
□ Point Mobility Analysis
• Dynamic Analysis

□ Frequency Response Analysis

□ Seismic Analysis Response Calculations
□ Harmonic Analysis
□ Random Vibration Calculations
□ Dynamic Stress Computations
□ Power Train Vibration Analysis
□ Shock Calculations per NAVSEA, DDAM,
MIL STD
• Non-Linear Analysis
□ Material Non-linear Analysis
□ Geometric Non-linear Analysis
□ FEA of Rubber & Elastomers
□ Non-linear Dynamic Analysis
□ Time Domain Response Analysis
□ Impact Analysis
□ Thermo-mechanical Analysis involving
large displacements
□ Elasto-plastic Deformation Analysis
• Analysis of Composites
□ Failure mode prediction of Composite panels
□ Filament Wound Composite – Anisotropic
material modeling
□ Random Fiber Composites
□ Stiffness, Deflection and Critical Load
calculation of Composite Structures
□ Metal Matrix Composites – Thermo mechanical
Analyses
• Thermal Analysis
□ Thermal Stress Analysis of parts and
assemblies
□ Transient Thermal Analysis
□ Thermo-mechanical Analysis
□ Coupled Thermo-fluid analysis
□ Natural and Forced Convection Analysis
□ Non-Linear Thermal analysis of curing
processes
□ Creep Analysis
• Fatigue Analysis (This my research
area)
□ Remaining Life Analysis ( RLA )
□ Durability Analysis
□ Failure Prediction Analysis
□ High Cycle Fatigue Calculations
□ Correlation to Real-world situations
□ Comparison of Alternate materials for
extended life and warranty
□ Life extension analysis
• CFD Fluid Flow Analysis
□ Pressure Drop Calculations
□ Conjugate Heat Transfer Analysis
□ Electronic Cooling Analysis
□ Thermal Efficiency Calculations
□ Fluid Flow simulation in Devices such as
pumps, valves, ducts, piping networks, fans,
diffusers, cyclones, blowers, heat
exchangers
□ Design optimization based on performance
prediction
• ASME Stress Analysis
□ Stress Analysis per ASME Codes
□ Nozzle stress analysis
□ Stress Intensity Calculations
□ Shell & Full Scale 3D Stress Analysis
of Pressure Vessels among others
• Design Optimization
□ Optimization of CAD Geometries
□ Weight Reduction Analysis
□ Value Addition & Value Engineering
Analysis
□ Sensitivity Based Optimization
□ Optimization of design variables based on
performance targets
Automotive
Applications
 In a vehicle having monologue construction, the body itself is connected to the
suspension. Therefore, the body panels are subjected to road loads. Hence,
stresses and strains in these body panels are of interest.
Figure 1 shows a FE mesh of a floor panel from the rear end of the vehicle. Provision
for spare wheel as well as the various depressions used as stiffeners can be seen in the
figure.
A total of about 13,000 quadrilateral and triangular shell elements have been used to
perform modal analysis, torsional stiffness analysis, and service load analysis.
The same finite element mesh is also used for crash analysis using LS-DYNA software.

Figure 1: Finite element model (MSC/NASTRAN) of the

floor panel of an automobile. (Courtesy: TELCO, Pune)
An automotive engine cylinder block
experiences severe pressures and
temperature gradients and other transient
loads.

It is essential to predict accurately the

stresses and the vibration levels for
further correlation with noise predictions.

Figure 2 shows a typical finite element

(shell element) model of a four cylinder
in-line diesel engine cylinder block. Figure 2: Finite element model of an
automotive engine cylinder block.
Such model is used to the (Courtesy: Mahindra and
a natural
predict frequencies and mode Mahindra Ltd., Nasik)
system response to combustion
shapes, gas
pressure, etc.
 Figures 3 to 6 show representative finite element models of various
components of a driveline where the gears have been modelled as friction
wheels.
Such a model can be used for studying the dynamic response of the entire
driveline.

Figure 3: Finite Element model of a

gearbox.
(Courtesy: Mahindra and Mahindra Ltd., Mumbai)

Figure 4: Finite Element model of a crankshaft.

(Courtesy: Mahindra and Mahindra Ltd., Mumbai)
Figure 5: Finite Element model of
differential.
(Courtesy: Mahindra and Mahindra Ltd., Mumbai)

Figure 6: Finite Element model of a rear axle.

(Courtesy: Mahindra and Mahindra Ltd., Mumbai)
Manufacturing
Process
Simulation
• Figure 7 is an illustrative example in which finite element tools have been
used for inverse analysis.

• A cylindrical slug is cold headed into the form of a near spherical ball.

• The coefficient of friction plays an important role in the final ball shape.
However, it is difficult to measure the value of coefficient of friction.

• To overcome this difficulty, the operation is simulated for various values of

coefficient of friction and the pole diameter (diameter of near flat portion
near the poles) is compared with the measured pole diameter in the actual
heading process for one case.

• This value is used for further analysis and optimization of the process.
Figure 7: Finite Element model of a
cylinder slug.
(Courtesy: TRDDC, Pune)
Figure 8 shows stress distribution in a fusion cast ceramic block.

A transformation behaviour of one of the components of the material mixture

causes anomalous expansion during cooling in a particular temperature range.

This leads to tensile stress build-up and failure on the cast block.

A 3D thermo-mechanical FE analysis is used to study the solidification, thermal

field and evolution of stress, and the cause for failure.

This information is further used to change the processing conditions so as to

eliminate these high tensile stresses.
Figure 8: Finite Element model of fusion cast ceramic block.
(Courtesy: Mahindra and Mahindra Ltd., Mumbai)
 Electrical
and
Electronics
Engineering
Applications
FEA can be used for reliability enhancement and optimization of insulation
design in high voltage equipment by finding accurately the voltage stresses and
corresponding withstands.
For complex configuration of electrodes and dielectric insulating materials,
analytical formulations are inaccurate and extremely difficult, if not impossible.

The FEA can be effectively used in such cases.

A typical equipotential field plot for a high voltage transformer obtained from
finite element simulation is shown in Figure 9.
An analysis of eddy currents in structural conducting parts and minimization of
stray losses in electrical machines is possible using FEM.
A typical mesh for one such analysis is depicted in Figure 10, where it is aimed
at estimating the eddy current losses in structural conducting plate supporting
high current terminations.
Figure 9: High voltage insulation design of transformer using FEA .
(Courtesy: Electrical Engineering Department IIT, Bombay)
Figure 10: Analysis of eddy currents using FEM.
(Courtesy: Electrical Engineering Department IIT,
Bombay)
• Thermosonic wire bonding is one of the preferred processes for completing
an electrical interconnection between a semiconductor chip and a lead
frame by a thin metal wire.

• The wire bonder machine (solid model shown in Figure 11) consists of a
linear motor driven precision XY-table on which a precision Z-axis assembly
integrated with an ultrasonic transducer is mounted.

• The silicon chip is mounted on a hot plate called heater block assembly
which is maintained at 200°C.

• The ultrasonic transducer helps in welding the gold wire to the silicon chip.

• The combined motion of the X Y and Z-axis helps achieve a curvilinear

profile to produce the required shape to the bonded wire.
Figure 11: Solid model of a wire bonder machine.
(Courtesy: ASM International Pvt. Ltd., Singapore)
• The present day needs of the wirebonder technology are quite challenging
and have to meet stringent process specifications such as small pitch
distance of 35 in between the successive bonds, stringent bond placement
accuracy of ±2 tm, and loop height consistency of 5 tm within a bonding area
of 70 mm x 70 mm.
• Additionally, to meet higher output, a bonding rate of 6-12 wires per second,
depending on the wire length range of 2 to 8 mm and wire diameter of 20 to
75 11m, is necessary.
• Since the bonding rate is high, the drive system experiences a peak
acceleration of 13 g (about 130 m/s2) in the XY-table.
• To achieve a position accuracy of within ±2 m, the residual vibration during
such a motion should be well within 0. 1 micron.
• Hence the design should be aimed at higher dynamic stiffness and lower
mass and inertia.
• The main objective of the finite element simulation (a typical mesh is shown in
Figure 12) is to analyse the dynamic rigidity of the system. A typical bending
mode of the machine is depicted in Figure 13.
 Figure 13: Second mode shape (114
Hz) of wire bonder machine.
(Courtesy: ASM International Pvt. Ltd.,
Singapore)

Figure 12: Finite Element model of a wire bonder machine.

(Courtesy: ASM International Pvt. Ltd., Singapore)
The next example relates to the dynamic analysis of a one-axis linear motor.

The one-axis table (the FE model in Figure 1.14) consists of a three-phase

linear motor that directly drives a 5 kg mass in rectilinear motion. The table is
designed for a peak acceleration of about 130 m/s2.

Further, the design would be used in a typical semiconductor packaging

machine such as the wire bonder (described above) which involves bonding
gold wires at a high speed of 12 wire interconnects per second.

Hence the finite element analysis aims at finding the resonant frequencies and
the mode shapes very accurately.

This will help in achieving a high dynamic rigidity with low mass. Also,
knowledge of the mode shape helps in illustrating the weakness in the design
for the various resonant frequencies.
This will help in achieving a high dynamic rigidity with low mass. Also,
knowledge of the mode shape helps in illustrating the weakness in the design
for the various resonant frequencies.

The model consists of a coil bracket containing the three coils and directly
connected to the dummy mass by four screws.

The table is guided by miter bearings which are modelled as equivalent springs
with appropriate spring constant which corresponds to the applied preload in
the bearings. A typical mode shape is shown in Figure 15.

Encapsulation of integrated circuits (IC) is commonly made using the transfer

moulding process where a thermoset epoxy is heated and transferred under
pressure so as to encapsulate the silicon IC chip.

The moulding machine consists of a top and a bottom mould mounted on large
platens.
The top plate is supported by four steel columns, while the bottom platen
guided by the four steel columns moves in a straight path using a motor-driven
four bar mechanism.

A very high pressure (equivalent load of about 100 tons) is maintained between
the top and the bottom mould faces, so as to avoid liquid mould compound to
leak at the interface.

Heaters are placed in the moulds to produce the heat necessary for maintaining
a constant uniform mould surface temperature of 175°C.

Such a uniform temperature enables uniform melting of epoxy and its smooth
flow into the mould cavities.
Figure 14: Finite Element model of a one-axis table.
(Courtesy: ASM International Pvt. Ltd., Singapore)
Figure 15: Natural frequencies and mode shapes of one axis table.
(Courtesy: ASM International Pvt. Ltd., Singapore)
A typical finite element model of the complete system is illustrated in Figure
16.
The top and bottom mould surfaces are coated with surface contact
elements in order to readily determine the contact pressure.
Further, thermal analysis of the model is conducted to predict the
temperature distribution on the mould surfaces.
Results also include the heat losses to the surroundings in the form of
convection and radiation heat transfer as well as conduction heat transfer to
the base of the machine.
Knowledge of these heat losses helps in deciding the number of heaters
and their locations as well as their corresponding wattage.
Figure 16: Finite Element model of a moulding machine.
(Courtesy: ASM International Pvt. Ltd., Singapore)