Introduction to Finite Element Analysis

using ANSYS
Sasi Kumar Tippabhotla
PhD Candidate
Xtreme Photovoltaics (XPV) Lab
EPD, SUTD

Disclaimer: The material and simulations (using Ansys student version) presented in this document are made purely for teaching and sharing knowledge and
NOT made for commercial use. The concepts and examples (other than author’s own research) presented here were taken from publicly available references or
internet. In both the cases, the original references / sources were properly acknowledged. This document is expected to be used only for personal learning /
teaching purpose.
Basic Idea of Finite Elements
No. of Elem 1 2 6

Element

Node

8 12 Circle Area Approximation

120
110
100

Area / Units
90
80
70
Actual Area
60 Area of Elements
50
40
0 2 4 6 8 10 12 14 16
No. of Elements
Finite Element Method
• A numerical method to solve (partial) differential equations
• Gives only approximate solution
• Applicable to several physical domains, for ex.
• Structural
• Thermal / Fluid
• Electromagnetic
• Coupled field
• Discretization of the structure into small portions – Elements
• Connecting points between elements – Nodes
Finite Element Analysis Procedure (Structures)
• Pre-processing
• Discretization of the structure – Meshing
• Assign element type and properties
• Assign material properties
• Apply Boundary conditions and Loads
• Solution
• Select the solver
• Calculate element stiffness matrices
• Assemble global stiffness matrix
• Solve for displacements, strains, stresses etc.
• Post-processing
• Display / Output displacements, strains, stresses etc.
• Calculate user defined parameters from the results
Finite Element Analysis Software
• Commercial / General purpose
• ANSYS – Simple, User friendly, low cost
• ABAQUS – Better solver, powerful for nonlinearities,high cost
• NASTRAN / PATRAN – Used for dynamics
• COMSOL – Multiphysics solver
• Altair Hypermesh / Optistruct – Good for meshing
• Open source / Free
• Cauliculix – Compatiable with ABAQUS
• GetFEM++ - Specially for Contact Analysis
• The list is not exhaustive, please find more in the link below
• https://en.wikipedia.org/wiki/List_of_finite_element_software_packages
Finite Element Analysis - Uses
• New Product Design
• Virtual Design of Experiments (DoE)
• Fatigue Life / Fracture estimation Reduces new
• Design Optimization product validation
• Identification of sensor locations for testing / testing costs
/ validation
• Sensitivity analysis
• Existing Product
• Feasibility of Repairs / Upgrades
• Product remaining life estimation
• Identification of maintenance intervals
• Failure root cause analysis
Mathematical Preliminaries of FEM – Differential Equation
Uniform bar with one end fixed and axially loaded on the other end and body load
As =* = *(du/dx) and assume fB(x) = b
X

x Boundary conditions This DE can be solved for exact

Essential: solution, U(x) = 2x – x2/2
but we shall find an approximate
Force balance in the small element solution now
Natural:

Assume a weight function, w such that

Note: the weight function should
Rearrange the terms satisfy the essential boundary
condition
Integrate over the entire body (i.e., limits)
Take limit, X  0
Weighted residual
formulation
Ref: Hughes, T. J. R., 1987, The Finite Element Method: Linear Static and
Dynamic Finite Element Analysis, Prentice-Hall, Inc.
 Mathematical Preliminaries of FEM – Variational Formulation
Assume an approximate solution, un

Weighted residual
formulation Variational Form / Weak Form of the Differential Equation

Advantages:
• No second order term – simple to solve numerically
• Symmetry
• Natural boundary condition is included, need not be
0
enforced.
• No double differentiation requirement for
displacement trail function

Ref: Hughes, T. J. R., 1987, The Finite Element Method: Linear Static and
Dynamic Finite Element Analysis, Prentice-Hall, Inc.
Mathematical Preliminaries of FEM – Numerical Solution
Uniform bar with one end fixed and axially loaded on the other end and body load
Approximate (Numerical) Solution
X With, A = E = L = b = P = 1 Substitute in the weighted
Let un(x) = x + a sin (x/2) residual equation

x = - a (2 / 4) sin (x/2)

Weigh function – Galerkin Method

w(x) = b sin (x/2) Un(x) = x + (16/3) sin(x/2)

(satisfies essential BC.)
Boundary conditions For simplification,
Essential: let A = E = L = b = P = 1
Exact solution:
Natural:
U(x) = 2x – x2/2

Ref: Hughes, T. J. R., 1987, The Finite Element Method: Linear Static and
Dynamic Finite Element Analysis, Prentice-Hall, Inc.
Different Types of Elements
1 D (line) Elements Special Purpose Elements
ek
Spring, Truss, Beam, Pipe etc. nj Point mass, Contact, Coupling, etc.
ni
ek
2 D (Plane) Elements nj
ni
Plate, Shell, Membrane etc.
nl
nk
3 D (Solid) Elements

3D continuum domains
Spring Element Formulation – Direct Method
Nodes
At node i
fi = -F = -k (uj – ui) = k ui – k uj

At node j
fj = F = k (uj – ui) = -k ui + k uj

Matrix Form

Nodal displacements

ku=F
Spring force, F

Element Element Element nodal

k stiffness nodal force vector
matrix displacement
vector
Spring displacement, u

Ref: Yijun Liu, Lecture Notes – Introduction to FEM, Uni. Cincinnati, 2002
Two Springs – Formulation of Global Stiffness Matrix
Use force equilibrium at nodes to assemble global stiffness matrix
At node 1
F1 = f11 = k1 u1 – k1 u2
At node 2
F2 = f21 + f12 = -k1 u1 + k1 u2 + k2 u2 + k2 u3
Stiffness Matrix: Element 1 = -k1 u1 + (k1 + k2 )u2 + k2 u3

At node 3
F3 = f22 = -k2 u2 + k2 u3

Stiffness Matrix: Element 2

Global Stiffness Matrix KU=F

Ref: Yijun Liu, Lecture Notes – Introduction to FEM, Uni. Cincinnati, 2002
Elastic Bar Element – Formulation
Nodal displacements At node i
fi = -F = -k (uj – ui) = k ui – k uj

At node j
fj = F = k (uj – ui) = -k ui + k uj

Matrix Form

Nodes

ku=F
Element Element nodal
Force, F

Element
k = EA/L stiffness nodal force vector
matrix displacement
vector
Displacement, u

Ref: Yijun Liu, Lecture Notes – Introduction to FEM, Uni. Cincinnati, 2002
Elastic Bar Element – Shape Functions
Nodal displacements

xi xj

What about displacements within the element?

Interpolate from the nodal diaplacements
Let u(x) = ax +b Rearranging terms will give
ui = a xi + b ---- (1) u(x) = ui (xj - x)/L + uj (x - xi)/L
Nodes uj = a xj + b ---- (2) = ui Ni + uj Nj
ku=F Solving (1) and (2)
Ni and Nj are shape functions
a = (uj - ui )/(xj - xi)
Some Rules:
Force, F

= (uj - ui )/L
k = EA/L • Ni + Nj =1
b = (uj xi - ui xj )/L
• At node i, Ni = 1, Nj = 0
• At node j, Ni = 0, Nj = 1
There fore
Displacement, u u(x) = x(uj - ui )/L + (uj xi - ui xj )/L
Ref: Yijun Liu, Lecture Notes – Introduction to FEM, Uni. Cincinnati, 2002
Solution Methods
Direct Methods Iterative Methods
• Solution time is proportional to NB2, N is • Solution time is unknown before hand
the size of the matrix and B is bandwidth • Suitable for large problems and bulky
• Suitable for small to medium problems structures
and slender structures (small band width) • Approximate, difficult to handle – depends
• Accurate, easy to handle on initial guess
• Requires large memory space • Reduces memory space requirement

Bandwidth

Ref: Yijun Liu, Lecture Notes – Introduction to FEM, Uni. Cincinnati, 2002
Solution Methods
Direct Methods – Gauss Elimination Iterative Methods – Gauss-Siedel

Ref: Yijun Liu, Lecture Notes – Introduction to FEM, Uni. Cincinnati, 2002
Examples: Airbus A320
High Stress Regions ??

Source: https://www.pinterest.com/pin/334392341058164942/
Examples: Jet Engine Failure Due to Drone Strike
Impact of a foreign object on an operating
jet engine – Can be catastrophic

Foreign object can be: a bird, debris, snow

ball, now recently drones

It is customary of engine manufacturers

like GE / Rolls Royce etc. to conduct tests
and FEA simulations of bird strike for
engine certifications

Source: http://www.uasvision.com/2015/11/09/drone-strikes-could-cause-jet-engine-failure/
Example: Spanner Stress Analysis

High Stress Region

Source: https://www.comsol.com/multiphysics/mesh-refinement
Example: Stresses in Silicon Solar Cells (Our Research)

Solder Joint

(µSXRD)

PV Mini Module (Experimental Sample)

µSXRD – Synchrotron X-ray Microdiffraction

For more details please refer: http://xml.sutd.edu.sg/publications

Ref: S. K. Tippabhotla et al., Progress in Photovoltaics 2017 (Article in press)

Example: Predicting Fracture of Micro Beam

Ref: Nagamani Jaya B et al., 2012, Philosophical Magazine, 92:25-27, 3326-3345, DOI: 10.1080/14786435.2012.669068
Introduction to ANSYS (Classic): Cantilever Beam
Consider the beam in the figure below. It is clamped on the left side and has a point force of 8kN acting
downward on the right end of the beam. The beam has a length of 4 m, width of 1 m and height of 0.2 m
(cross-section is a rectangle). Additionally, the beam is composed of a material which has a Young's Modulus
of 2.8x10^10 Pa. Using ANSYS, calculate the following:
1. Deformation of the beam
2. Maximum bending stress along the beam
3. Bending moment along the beam

1m
0.2 m

More Examples @: https://confluence.cornell.edu/display/SIMULATION/ANSYS+Learning+Modules

Step1: Preferences
Step1: Define Element Type
Step1: Define Element “Key Options”
Step1: Define Material Properties
Step1: Define Geometry of the Beam
4m
X
0.2 m

Y
Step1: Define Element Size – Along Beam
1 2

3 4
Step1: Define Element Size – Across Beam
1 2

3
Step1: Mesh – Mapped mesh by corners
1 Select the area by clicking on it (notice change
of colour?)
2 Pick corners in cyclic order
Step1: Mesh – Define Analysis Type
Step1: Mesh – Define BC
1 2

3
Step1: Mesh – Define Load
1 2
Step1: Mesh – Solution
Step1: Results – Displacement, uy
Step1: Results – Stress, Sxx
Mesh Refinement: Spanner Stress Analysis

High Stress Region

Source: https://www.comsol.com/multiphysics/mesh-refinement
Exercise – Stress concentration in Plate with a Hole
Eqv. Stress
6m

1.5 m Radius 500 mm

1 kN
4m

All DOF = 0 2m

Thickness = 500 mm
Material:
Steel
E = 200 GPa
Mu = 0.3
Some common mistakes
• Inconsistent units
• Wrong boundary conditions
• Wrong material property assignment
• Wrong element type assignment
Thank You