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 1 JANUARY 2024  BY OMOTORIOGUN VICTOR

Common Errors in Finite

Element Analysis and How to
Avoid Them
This article explores some common errors that can be
encountered in finite element analysis of structures and
some strategies to avoid them.

Finite Element Analysis (FEA) of structures is a numerical technique

used to predict the behavior of complex engineering systems under
various conditions. This powerful computational method finds
application in structural engineering, mechanical engineering, and
other disciplines for simulating how structures respond to loads,
including forces, pressures, and thermal effects.

···
We cannot talk about how engineering software became a significant
tool in engineering without mentioning finite element analysis.
Engineers have always had ideas and concepts of complex structural
systems, however, without the requisite method of solving the
analysis problems required to birth the concepts, the concepts and
ideas were simply cosigned to oblivion. However, things changed with
the advent of finite element an alysis in the 1940s. Many of the
engineering problems engineers thought had no definite solutions
have now been solved.

What is Finite Element Analysis?

In FEA, a physical structure is divided into smaller, simpler elements,
then mathematical models are applied to each element. These
elements are interconnected at specific points called nodes , forming
a mesh that represents the entire structure (Figure 1). The behavior
of each element is analyzed using mathematical equations, taking into
account material properties, geometry, and boundary conditions.
···
Figure 1: Meshing

The governing equations for each of the elements are then combined
to create a system of equations that represents the entire structure.
These equations are solved using numerical methods to obtain the
displacements, stresses, and other relevant information at each node
in the mesh. Thus, the results obtained provide insights into the
structural response, including deformations, internal forces, and
possible failure points.

FEA allows engineers to assess the performance and safety of

structures without physical prototyping, saving time and resources. It
is widely used in the design and optimization of various engineering
components, ranging from simple beams to complex aerospace
structures. FEA can simulate diverse physical phenomena, including
static and dynamic loads, thermal effects, and fluid-structure
interactions.
However, despite its power, FEA requires careful consideration of
various factors, such as mesh quality, boundary conditions, and
material models, amongst other to ensure accurate and reliable
results. Like any numerical technique, FEA is prone to errors that can
compromise the accuracy of results. Thus, in this article, we will
explore some common errors that can be encountered in finite
element analysis of structures and some strategies you can deploy
towards avoiding them.

···

Common Errors in Finite Element Analysis

The typical errors associated with other traditional methods of
analysis such as improperly defined material, incorrect member size,
inaccurate loading and so on can also be found in finite element
analysis. However, there are certain errors that are more specific to
finite element analysis. These errors can be sub-divided into two
groups: Meshing errors and errors arising from incorrect boundary
conditions. This article will focus on meshing and boundary errors as
the former are more readily addressed.

Meshing Errors

Perhaps the biggest and the most prominent causes of error in 2D FEA
models is meshing. Meshing is one of the fundamental steps in FEA. It
is where the structure is divided into smaller analysis elements.
Inaccurate meshing can lead to significant errors in results. Common
meshing errors include:

Distorted Elements: Elements with highly distorted shapes can result

in poor accuracy. Distorted mesh elements may lead to singularities
and numerical instability. Ensuring that elements maintain reasonable
aspect ratios and avoiding highly skewed shapes is very crucial.
Aspect Ratio: An excessively high aspect ratio of meshes (ratio of the
longest side to the shortest side) can cause numerical instability and
inaccurate results. Ideally, elements should have reasonably uniform
aspect ratios to maintain solution accuracy.

Under-meshing: Using elements that are too large in regions with

complex geometry or high stress gradients may result in an
insufficient representation of the structural response. This can lead to
inaccurate results, especially in areas with localized stresses or
deformations.

Over-Meshing: Similarly, excessive mesh refinement presents no

benefit. It leads to increase computational costs without a

···
proportional improvement in accuracy. It can also introduce artificial
stiffness and alter the behavior of the structure.

Abrupt Changes: Sudden transitions in element size or type can

introduce errors. Gradual mesh refinement or coarsening is often
preferred to ensure a smooth transition and accurate representation
of the structural response.

Mesh Discontinuities: Failure to accurately capture material

interfaces or structural changes can result in errors. Special attention
should be given to meshing around regions with significant material
inhomogeneity or geometric changes.

Mesh Sensitivity: The solution should be relatively insensitive to

changes in mesh density. If the solution changes significantly with
mesh refinement, it may indicate convergence issues or the presence
of mesh-dependent errors.

How to Avoid Meshing Errors

In other to avoid meshing errors in FEA, here are some tips that may
assist you:

Understand the Geometry: The first step towards addressing an

error due to meshing in a FEA model is to first understand the
geometry you’re working with. Having a good and thorough
understanding of the geometry ensures that you can predict the
critical regions of high stresses and identify places where a refined
meshing will be required.

Choose an Appropriate Element Type and Order: Avoiding distorted

shapes, excessive aspect ratio, under meshing or even over meshing is
contingent on the order and element type used for the finite element
analysis. Make sure to always choose the appropriate element type for
your analysis (e.g. tetrahedral, hexahedral, or triangular elements).
Different types have different accuracy and computational efficiency.
Thus, an in-depth understanding of FEA is required to use FEA
software.
Mesh Refinement: Understanding the geometry will help you to
select the appropriate order and type of mesh required for an analysis.
However, it is refinement that actually fixes any issue that may arise as
a result of geometrical considerations. To obtain an accurate result,
you must refine the mesh in critical regions, particularly in locations
where high gradients or complex stress distributions are expected.
Adaptive meshing techniques are available today in many FEA
software today, that can help you.

Use Quality Meshing Software: Lastly, addressing meshing errors is

impossible if you use a very prohibitive software that does not give
you control over the aforementioned solutions. Thus, it is very
important to invest in high-quality FEA software that allows for easy
control over mesh size and refinement. A very good FEA software
packages will often come with robust meshing capabilities.

Incorrect Boundary Condition

The second class of common errors found in finite element analysis

result from an engineer applying an incorrect or unrealistic boundary
condition to an FEA model.

···

Since finite element analysis is a numerical method of analysis, it

follows that boundary conditions must be applied to arrive at a
definite outcome. However, applying an incorrect boundary condition
will only produce an unrealistic analysis outcome and
misinterpretations of the actual structural behaviour. Some of the
common errors typically encountered in FEA due to incorrect
boundary conditions include:

Incomplete Constraints: The laws of statics are always right! Failing to

adequately constrain all degrees of freedom would only lead to rigid
body motions, resulting in unrealistic deformations and stress
× are applied to
distributions. It is crucial to ensure that all restraints
prevent unintended structural deformation.

Over constraint: Applying excessive constraints can lead to over

constraint issues, causing singularities, convergence problems, and
inaccuracies. Careful consideration and validation of applied
constraints are essential to avoid unnecessarily restricting the system.
Incorrect Constraint Types: Choosing the wrong type of constraint
for a specific problem, such as fixing a degree of freedom that should
deform or applying an incorrect support type, can yield inaccurate
results. Precision in selecting and applying constraints is crucial.

Dependency on Reaction Forces: Relying solely on reaction forces

for constraints without considering the equilibrium of internal forces
can introduce errors. Proper understanding of the structural response
involved, and realistic application of constraints are necessary for
accurate analysis results.

Inconsistent Mesh and Boundary Conditions: Finally, inconsistencies

× can lead to errors.
between the mesh and applied boundary conditions
Ensuring proper alignment of the mesh with the geometry and
consistent application of boundary conditions to corresponding nodes
and elements is essential for accurate FEA results.
 How to Avoid Incorrect Boundary Conditions

Addressing boundary condition error in a finite element model

requires the engineer to consider the following:

Thorough Understanding of the System: First of all, gain a

comprehensive understanding of the physical system you want to
model. This includes recognizing expected behaviors, critical loading
conditions, and the appropriate constraints required for an accurate
analysis result.

Complete and Consistent Constraints: Ensure that all degrees of

freedom are adequately constrained. Incomplete constraints will only
lead to rigid body motions and inaccuracies as aforesaid. Additionally,

···
maintain consistency between the mesh and applied boundary
conditions, ensuring that constraints are appropriately applied to
corresponding nodes and elements.
Avoid Over constraint: Be cautious not to over constrain the system
by applying excessive constraints. Over constraint would cause
convergence issues and thus, inaccurate results. Carefully validate and
select the minimum set of constraints necessary to accurately
represent the structural problem.

Correct Constraint Types: Choose the correct type of constraint for

each situation. Understand the differences between fixed supports,
roller supports, etc. Applying the wrong type of constraint would only
introduce errors into the results.

Regular Validation of Results: Regularly validate FEA results against

known analytical solutions, empirical data, or rules of thumbs.
Consistent validation helps ensure that the chosen boundary
conditions are appropriate and representative of the structural
system.
 ×

See: Top 10 Structural Engineering Software of 2023

Conclusion

Despite its power, Finite element analysis requires careful

consideration of various factors, such as mesh quality,
boundary conditions, material, loading, geometric
parameters amongst other to ensure accurate and reliable
results.
In structural engineering, Finite Element Analysis (FEA) is a valuable
tool, but its effectiveness relies on accurately representing the
structural system and carefully considering all factors that affect
results. To enhance the reliability of FEA model results, engineers
must keep an eye on the common errors detailed in this article. And in
addition to the steps listed for avoiding these errors, engineers should
ensure that they validate their models against the conservative, less
rigorous analytical analysis methods, and stay updated with
advancements in FEA.

POSTED IN ANALYSIS, STRUCTURES • TAGGED FINITE ELEMENT ANALYSIS

Published by Omotoriogun Victor

A dedicated, passion-driven and highly skilled engineer with extensive

knowledge in research, construction and structural design of civil
engineering structures to several codes of practices View all posts by
Omotoriogun Victor

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