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Introduction
Overview
This course is taught with a mix of theoretical information and applied th ti l i f ti d li d finite element analysis (FEA). Concepts are ill t t d with simple, C t illustrated ith i l hands-on exercises. Models are created which illustrate a broad range of topics including theory, element types, analysis types, meshing techniques, results evaluation and more.
What is FEA?
FEA is a mathematical solution to engineering l ti t i i problems where a physical model is divided into discrete components. p FEA models are defined by nodes and elements (commonly called a mesh).
What is FEA?
Basic engineering equations, such as Hookes ti h H k law, are solved at the nodes and elements. A matrix equation with terms from each element is solved. solved
What is FEA?
Predicts change within the element (e.g., deformation, l t( d f ti stress). The results are plotted on the model by color to show the lowest and highest values. values
Provides a non-destructive means of t ti products. f testing d t Faster prototyping for p yp g what if scenarios. Design optimization. optimization Speed up time to market by shortening the design cycle.
Best Practices
FEA requires engineering judgment. In the best case, you should know the approximate answer before you begin. Proper selection of elements materials elements, materials, loads, constraints and analysis parameters comes from experience experience.
Best Practices
Understand that the computer model never matches reality (its (it s only an approximation). The surest route to failure in FEA is to underestimate the complexity of the technology. technology
Automotive Industry Danly Engineering Services, Division of Services Enprotech Mechanical Services, Inc.
The above illustration shows how engineers analyzed
a power press with additional cutouts.
Biomedical Industry Ophthalmic Consultants of Boston and the Tufts University School of Medicine y
The above illustration shows stresses on an eye as it
underwent a 30 saccadic eye movement. This was modeled to help understand why retinal detachments occur.
Build/Mesh a Model
Define FEA Model Analysis and Element Types Define Loads and Constraints
Create Mesh in CAD Solid Model or FEA Editor Environment Setup Analysis Type, Element Type and Materials in the FEA Editor Environment Apply Loads and Constraints in the FEA Editor Environment Analyze Model (Solve)
F E M P R O
Review Results in the Results Environment and Create an HTML Report in the Report p p Environment
FEMPRO Interface
A. Title bar B. Menu bar C. Toolbars D. Tree view E. Working area F. Miniaxis G. G Design scenario toolbar H. Status bar
Create Mesh
FEA Editor Environment Assign element types and parameters. Assign material properties. Apply loads and constraints. Assign analysis parameters. Analyze the model.
Review Results
R Results E i lt Environment t Review the model setup. Review the analysis results results. Create images or animations of results.
Present Results
Introduction Example
Select File: Open.... p Change the file type to IGES (*.igs, ( .igs, *.iges). Select MotorMount.IGS.
Creating a Mesh Create a mesh by pressing the Mesh g model button in the Model Mesh Settings dialog. S tti di l
Applying the Materials Select all three parts by clicking on the y g part names in the tree view while holding d h ldi down the th <Ctrl> key. Right click on the name and select Modify: Modify: Materials.... Select Steel (ASTMSteel (ASTM A36) from the list.
Applying the Loads Use the surface selection option. Select the two top surfaces of the brackets. After the surfaces are selected, right click and select Add: Surface Pressure/Tractions.... Enter a pressure of 20 psi.
Applying the Constraints Select the surfaces in the holes of the shaft. After the surfaces are selected, right click and select Add: S rface Add Surface Boundary Conditions... Conditions . Press the Fixed button and then the OK button.
Reviewing the Results Run the analysis by selecting Analysis: g y Perform Analysis.... Once the analysis is complete, the von Mises stress results will appear. ill appear
Creating a Report Select the Report tab at the bottom of the screen. Select the HTML Report heading. Right click and select the Report Wizard command. Thi will take you This ill t k through a five-step wizard and produce an HTML report.
Presentation of Results
FEA Concepts
What is a DOF? The unknowns in a finite element problem are referred to as degrees of freedom (DOF). g ( ) Degrees of freedom vary by element and analysis type.
What is a DOF?
Uy
Rot y
Node
Rot z Uz
Rot x Ux
Node
A node is a coordinate location in space where the DOF are defined. Th d fi d The DOF of this point f thi i t represent the possible response at this point due to the loading of the structure.
Element
An element is a mathematical relation that defines how the DOF of a node relate to the f d l t t th next. These elements can be lines (beams), areas ( (2-D or 3-D plates) or solids p ) (bricks and tetrahedrals).
A node has a given set of DOF, which characterize the response. For structural p analyses, these DOF include translations and rotations in the three global directions. The type of element being used will also characterize which type of DOF a node will yp have. Some analysis types have only one DOF at a y yp y node. Examples of these analysis types are temperature in a heat transfer analysis and velocity in a fluid flow analysis.
Element Connectivity
Elements can only transfer loads to one another via common nodes.
No Communication Between the Elements Communication Between the Elements
= E
F A
L 0
dx
FL = E
Stress Basic equations do not require the use of a computer to solve. solve Computer-based analysis is needed when complexity is added as follows: Geometric complexity makes the elasticity
equation difficult or impossible to solve. q p Variations in material properties exist throughout the part.
General Case
To determine the displacement of a simple linear spring under load, the relevant equation is:
Unknown
This can be solved with matrix algebra by rearranging the equation as follows:
-1 1
Calculation of and
Strains are computed based on p the classical differential q p y equations previously discussed. Stress can then be obtained from the strains using Hooke s Hookes law (F = kx).
Dynamic Equation For a more complex analysis, more terms are needed. This is true in a dynamic analysis, which is defined by the following equation:
Other Applications
1 4
F L
Element 1
0 0 0 1 6 30 x10 (2 ) k= 0 0 120 0 1
0 0 1 0 0 0 1
Element 2
Element 3
1 30 x106 (2 ) 0 k= 1 120 0
0 1 0 0 0 1 0 0
0 0 0 0
F L
0 10,000 F2 x F2 y F= F3 x F3 y F 4x F4 y
D1x D 1y 0 0 D= 0 0 0 0
ALGOR Model
ALGOR Results
Analysis Options
The first decision in the FEA process is to decide what type of analysis you need to run. The analysis type will dictate what yp y type of results you will obtain. For example, if you need the displacement of your part, then you will need to run a structural analysis.
Analysis Options
Linear
Electrostatic
C Current and voltage d l Field strength and voltage
Multiphysics u t p ys cs
Steady coupled fluid flow and
thermal
Nonlinear static MES Steady-state heat transfer Transient heat transfer Steady fluid flow Unsteady f fluid f flow Flow through porous media
Fluid Flow
Structural
Structural
Linear dynamics
N t l frequency (modal) Natural f ( d l) Response spectrum Random vibration Frequency response Transient stress (direct integration) Transient stress (modal superposition) Critical buckling load Dynamic Design Analysis Method
(DDAM)
Structural
Fatigue
Product life cycle simulation (failure). (failure) Stress-based fatigue life calculation. Strain based fatigue life calculation. Strain-based calculation
Structural
Nonlinear/MES
Li Linear and nonlinear material models. d li t i l d l Large deformation and strain. Failure due to:
yielding. Local and structural buckling. Permanent deformation residual stress. Large-scale motion.
Material
Structural
Nonlinear/MES
S f Surface-to-surface contact t f t t Impact C Creep
Thermal
Time-varying conditions
Fluid Flow
Steady fluid flow Unsteady fluid flow Flow through porous media
Electrostatic
Element Options p
Analysis type selected. How you create y y your mesh. Assumptions you can make
about geometric properties properties.
Element Categories
Line Elements: A line connecting 2 nodes (beams, trusses, springs, actuators, pipes, etc.) Area (2-D) Elements: A cross-section p of a part. Must be 3 or 4 lines enclosing an area.
Element Categories
Area (3-D Planar) Elements: Midplane of a part in space. Must be 3 or 4 lines enclosing an area. 3-D Solid Elements: Must be 4, 5, 6 g or 8 nodes enclosing a volume.
four (quadrilateral) undivided line segments. If a side consists of multiple line segments, the region is invalid. segments invalid
Certain shapes can create elements p which are not recommended for FEA y g g analysis. The following regions will be eliminated:
Regions eg o s
with a y co ea o t any collinear or concave sides. with a highly nonflat curvature in a 3-D drawing.
Regions
Meshing Guidelines
Meshing can be completed either by using automatic mesh engines or by creating a mesh by hand. Automatic mesh generation is usually p completed on CAD solid models. Hand meshing is usually done on simple models that require a structured mesh.
Hand Meshing
There are two types of hand meshing: building from scratch and building from a wireframe. Building from scratch: Draw the elements by hand one at a time to create a structured mesh. Building from a wireframe: Build a 2-D or 3-D wireframe of the model and use an unstructured mesh engine to d t t d h i t generate the internal elements.
You will have to decide what type of loads and constraints will properly define the engineering criteria for the model. model In FEA, there are different types of loads and constraints for each analysis type type. Applying the proper loads and constraints is one of the most important factors in getting the correct answer. Always double check your model model.
There are multiple ways to p y apply different loads and constraints to a model: Nodal Edge Surface Element
Boundary Conditions: y Prevent specified DOF from g g undergoing translation or rotation in a specified direction. Boundary Elements: Act like a spring with a specified stiffness along a specified direction.
the line of symmetry, boundary conditions must be applied to represent the symmetrical part:
Out-of-plane displacement = 0 Two in-plane rotations = 0 T i l t ti
Line of Symmetry
Plane of S Pl f Symmetry
Boundary Conditions
Proper boundary conditions are necessary for an accurate analysis. The global stiffness of the system must be modeled correctly for any local behavior to be captured correctly.
Boundary Conditions
The two most unwanted FEA effects to watch out for are:
Overstiffening Understiffening Unlike the real-world equivalent, constraints in FEA are perfect perfect.
to the face of plate, composite and brick elements. Applied to the edge of 2-D and membrane elements elements.
Surface Force
Can
specify magnitude and direction of a force that will be evenly distributed over a given surface.
a function of the position that controls the magnitude of the load over the surface surface.
Gravity y
Can
specify gravitational value and direction. You must have a mass density defined for each part. part center of rotation angular velocity rotation, and acceleration values.
Centrifugal Loads
Specify
Distributed Loads
Specify
Truss Elements
Truss Elements
Truss elements are two-node members, members which allow arbitrary orientation in the X, Y, Z system. The truss transmits axial force only, and in general, is a three DOF element (i.e., three global l t (i th l b l translation components at each end of the member). Trusses are used to model structures such as towers, bridges and buildings. b ildi
Truss Elements
Objective: Construct and analyze a frame of truss elements loaded with 2 nodal forces. Geometry: Cross-sectional area = 1 in2. Material: Aluminum (6061-T6). Loads: Nodal forces as shown in the image to the right. Constraints: Fully fixed at Point A. A Ty and Tz constrained at Point G. The rest of the model will have Tz constrained.
Beam Elements
Beam Elements
Beam elements are slender structural members that offer resistance to forces and bending under applied loads. B Beams are f found i building d in b ildi frames, transmission towers and bridges. bridges A beam differs from a truss in that a beam resists moments (twisting and bending) at the connections.
Beam Elements
Beams use a third node to define the orientation. Cross-sectional properties Cross sectional are defined for bending about both the strong and weak axes.
Beam Elements
length of the element is much greater than the width or depth. g p element has constant crosssectional properties. p p element must be able to transfer moments. element must be able to handle a load distributed along its length. g g
Objective: Determine the maximum deflection of the beam due to its own weight. Geometry: W10 x 100 crosssection. Material: Steel (AISI 4130). Loads: Gravity in the -Y direction. Constraints: Each end has constraints against all DOF except for Rz.
2-D Elements
2-D Elements
Two-dimensional elements are three- or l t th four-node elements that are f formulated in the Y-Z l t d i th Y Z plane. They are used to model and analyze d l d l objects such as bearings, seals or structures such l t t h as dams.
2-D Elements
2-D Elements
Create wireframe sketches for each part in the FEA Editor environment. Use the 2-D mesh engine to generate the 2-D elements elements.
Objective: Determine the hoop stress at the inner radius of the cylinder from the applied pressure load. Material: Steel (AISI 4130). Loads: Uniform internal pressure of 10,000 psi. Constraints: The bottom edge g will have Tz constraints.
Plate Elements
Plate/Shell Elements
Plate/shell elements are three- or four-node four node elements formulated in three-dimensional space. These elements are used to model and analyze objects such as pressure vessels and automotive body parts. A thickness is assigned to the elements. Stresses will vary linearly through the thickness. h hi k
Plate/Shell Elements
Membrane Elements
Three- or four-node elements formulated in three-dimensional three dimensional space. Used to model "fabric-like" objects such as tents or cots, or structures such as the roof of a sports stadium. Model solids of a specified thickness, which exhibit no thi k hi h hibit stress normal to the thickness.
Composite Elements
There are two types of composite elements: it l t thin or thick. Each element can have multiple lamina with different material properties and fiber orientations. Multiple failure criteria are available.
Objective: Determine the maximum stress in the plate from the applied pressure load. Geometry: The plate is 10 x 5 x 0.25. Material: Steel (AISI 4130). Loads: Uniform pressure of 50 p psi. Constraints: The two long edges will have Ty and Tz constraints. constraints One short edge will have Tx and Tz constraints.
Brick Elements
Brick Elements
Brick elements are four-, five-, four- five- six- or eight-node elements formulated in threedimensional space. Brick elements should be used when the stress through the thickness of a part is important. important
Objective: Determine the maximum bending stress in the beam from the applied load. Material: Steel (4130). Loads: 10,000 pounds , p distributed across the free end. Constraints: The center row of nodes at the fixed end will be fully constrained. The rest of the nodes at the fixed end will have Tx constraints.
Objective: Analyze a beam model using different element types and compare the results. Material: Steel (AISI 4130). Loads: 100 psi in the -Z direction on the top of the beam. Constraints: Fixed at the left end and simply supported at the right. Elements
2-D: Apply a 100 psi pressure to p g the top edge. Plate: Model the 10 x 0.5 dimensions with a thickness of 0.25. Apply nodal forces equivalent to the pressure load. i l t t th l d The forces at the end nodes should be half the magnitude of the forces at the interior nodes. Plate: Model the 10 x 0.25 dimensions with a thickness of 0.5. Apply a 100 psi pressure load t th t l d to the top. Brick: Apply a 100 psi pressure to the top surface.
Comparison of Results
Element Type Beam 2-D Plate 0.25 Thick Plate 0.5 Thick Brick
(psi)
xy y
(psi)
y (near
1780
341
2363
16875
Mesh Convergence
Mesh Convergence
For mesh convergence testing, it is suggested that you run at least three analyses at different mesh sizes:
Mesh Convergence
Usually, you will not see the direct equation solutions (such as displacements) change with the different mesh sizes. You will see the numerical method answers (such as ) g stresses) converge to an answer as the mesh gets finer.
y max (psi)
3460.58 3448.13 3502.20 3538.23 3556.18
Build a solid model in any CAD solid modeler. Using direct CAD/CAE data g exchange or a universal file (IGES, , ), p STEP, ACIS), open the model. Create a mesh on the model.
Mesh Refinement
To optimize solution time, it is useful to create a fine mesh in areas where the results are critical and a coarser mesh in areas where the results will not be as high. You can add refinement points p to achieve localized refinement.
Midplane Meshing
for information on creating plate element models from CAD solid models.
Assembly Meshing
When working with multiple parts in an assembly, it is critical that the assembly meshes match between the parts if they are bonded together. together If the area where the parts come together should not be bonded, t th h ld t b b d d then contact should be used to account f th i interaction. t for their i t ti
Any combination of element types is possible in an assembly. y Nodes must be matched where the parts meet in order for loads to be transferred. The available DOF of the element types that are connected must be considered to avoid unstable geometry.
Refer to the Combining Beam Elements with CAD S lid Models Tutorial ith Solid M d l T t i l available at
www.algor.com/service_support/tutorials
Contact
Select surfaces in the CAD Solid Model environment and specify that contact be considered. The nodes on the surfaces will be able to move apart from each other with no restrictions. The nodes will translate loads when they move together. An iterative solution is used to determine which nodes are in contact. Contact is not considered during the first iteration. Therefore, it may be necessary to apply weak elastic boundary elements to ensure stability. stability
Loads: 1,000 pounds will be applied in the Y direction at the end of the lever. Surface contact should be defined between the handle and the lever, the handle and the pins and the lever and p the pins.
Solving Options
Introduction to Solvers
There are many different ways to solve the matrices that were discussed earlier. As computers get faster new faster, technologies are used that create faster processing of the equations. equations You should usually accept the default settings, which are optimized for the fastest processing.
Solver Options
Sparse
Solves only non zero equations non-zero Skyline Variable bandwidth Banded Fixed bandwidth Iterative Requires a tolerance and initial
conditions
Results Evaluation
Result Options
The types of results depend on the type of analysis that is performed. For example, a structural analysis g y p will give you displacement and stress results while a thermal y give you temperature y p analysis will g and heat flux results.
The results are either calculated directly through linear equations g or calculated through numerical integration methods. For example, displacements are calculated directly from Hookes law, but strains are calculated through numerical methods.
The best method for justification is to run the model with different mesh sizes. R Remember, you are approximating an b i ti area or volume with the elements. The better the quality of the elements, the better the results. Usually a fine mesh will give more accurate answers than a coarse mesh.
Structural Results
Presentation P i of Results
Presentation Guidelines
Use colors that will stand out from each other. other Make presentations that everyone can understand. understand Remember that many people looking at engineering reports are not engineers. Have a standard template. Include 3 D representations with 3-D charts and graphs.
Presentation Options
Contour Images
Animations
Time-Dependent Plots
Report Generation
Thermal Elements
The thermal rod, 2 D, plate 2-D, and brick elements are geometrically identical to the structural elements.
Initial Temperature
Specify
a certain temperature that an area will begin the analysis at (transient analysis).
Applied Temperature
Specify
Convection
Assign
a convection coefficient and the ambient temperature. the radiation function and the th ambient temperature. bi t t t the amount of heat added or removed per unit area.
Radiation
Assign
Heat Flux
Assign
Heat Generation
Enter
Body-to-Body Radiation
Select the surfaces that will exchange heat through g radiation and assign an emissivity value. The processor will automatically calculate the view factors between elements.
Thermal Contact
Used to simulate imperfect thermal conduction between two parts or a substance between two parts that is not modeled (i.e., epoxy). Define contact pairs in the CAD Solid Model environment environment. Define the resistance value between the surfaces. f
Forced Convection
Perform a fluid flow analysis. Apply the velocity profile as input for the heat transfer analysis. Th convection generated by the The ti t d b th velocity profile will be applied to the model during the analysis. d l d i th l i
Thermal Results
Electrostatic Elements
The electrostatic 2 D and brick 2-D elements are geometrically identical to the structural elements.
Applied Voltages pp g
Temperatures p
Electrostatic Results
Electrostatic Analysis
The fluid flow 2 D and brick 2-D elements are geometrically identical to the structural elements.
Prescribed Velocity C b used to specify an inlet Can be dt if i l t F Curves Fan C Can be used to model flow
velocity or zero velocity along a wall. generated by intake, exhaust or internal fans. i t lf rotating machinery.
Pressure
Multiphysics
A multiphysics analysis combines the effects of multiple analysis types. y y The original analysis is performed. Another analysis is set up using the results y p g from the original analysis as the loading in the subsequent analysis. For some analyses, iterations are required to reach a steady solution. Steady coupled fluid flow and thermal analysis solves for fluid and thermal results simultaneously. i lt l
Apply temperature results from a heat transfer analysis to a stress analysis to analyze thermal stress. l th l t Apply current results from an electrostatic analysis to a heat transfer analysis to analyze Joule heating. Apply velocity results from a fluid flow pp y y analysis to a heat transfer analysis to analyze forced convection. A l t Apply temperature results from a heat t lt f h t transfer analysis to a fluid flow analysis for natural convection.
Refer to the Static Stress with Linear Material M d l /M lti h i T t i l M t i l Models/Multiphysics Tutorial available at
www.algor.com/service_support/tutorials
Material Models
Material models are subsets of the element types. types These properties allow you to make decisions on what type of material properties will be used for each part in the model. For example, if a part will see the plastic region of a stress versus strain curve, you should select one of the von Mises material models for an elastic/plastic analysis. l i
Isotropic
This is the standard material model. The material properties d l Th t i l ti are independent of direction.
Orthotropic
This material model can have different properties i th th diff t ti in the three orthogonal directions. The required properties are identical to the isotropic material model. However, you enter separate values for the three directions.
Temperature-Dependent
For some elements, the properties for both isotropic ti f b th i t i and orthotropic materials can b defined on a be d fi d temperature basis. The values are linearly interpolated between the temperature points.
These material models allow you to specify a bilinear curve. A modulus if bili d l for the elastic region, a yield point and a modulus for the plastic region d d l f th l ti i will be defined. These material models also allow you to define a stress-strain curve if the material cannot be modeled with a bilinear curve.
These material models are used to simulate rubberdt i l t bb (hyperelastic) and foam-like materials. t i l The hyperfoam model will include compressibility effects.
Drucker-Prager
These material models are used t account for rated to tf t dependent material behavior due t di i ti l d to dissipative losses due d to viscous effects. These material models can be used to model thermal creep.
Piezoelectric
This material model is used to t model parts that d l t th t experience stress due to a voltage distribution. lt di t ib ti
Curve
This material model allows you t i to input a bulk modulus t b lk d l versus strain curve to control the behavior of the t l th b h i f th part.
Refer to the Static Stress with Nonlinear Material M d l T t i l M t i l Models Tutorial available at il bl t
www.algor.com/service_support/tutorials
Kinematic Elements
Kinematic elements can be either 2- or 3 D elements. 3-D elements Kinematic elements do not experience strains and do not report stresses stresses. Otherwise, these elements behave just like flexible brick elements. They have an advantage over flexible brick elements because of their small contribution to the size of the global stiffness matrix. This results in faster run times.
Contact Elements
Contact elements can have different stiffness values in compression and tension. tension These elements can also have a breaking stress at which point the stiffness will be zero zero. These elements can be used to simulate cables.
Coupling Elements
Coupling elements aid in the simulation of parts that "couple" at a known length. Thi coupling is modeled This li i d l d by introducing a stiffness when it reaches this l h h thi length. th This stiffness is calculated using the modulus of i th d l f elasticity, a coupling area and the length of the d th l th f th element.
Dashpot Elements
Dashpot elements can be used to apply local damping to a model. You can specify a p g damping coefficient that will control how much these elements affect motion.
Actuator Elements
Actuator elements are line elements whose lengths can change over time time. They are used to simulate defined movement of a part (e g (e.g., hydraulic cylinders or solenoids).
Slider Elements
A slider element consists of two collinear lines connected at one node. The node in the middle will be allowed to move along the line defined by the other two points, letting the node slide slide such as a slot.
Pulley Elements
Pulley elements consist of three nodes: driver, pivot and slack. As the driver node moves toward or away f from th pivot, the i t the slack node will move in the opposite direction by a set relationship. relationship
Pipe Elements
Pipe elements allow you to model piping systems under internal pressure loads. The pipe elements can be either straight sections or bends.
Hydrodynamic Elements
Hydrodynamic elements can be either 2- or 3-D elements. Th These elements allow l t ll for the simulation of the i t th interaction of fluids ti f fl id with solids without considering the details id i th d t il of the flow.
Impact Planes
Specify a wall or floor parallel to the global X, Y and Z axes. Objects will not be able to pass through this plane.
Surface-to-Surface Contact
Specify two or more surfaces that may come into contact during the event duration. Can include static and dynamic friction effects effects.
for information on performing a Mechanical Event Simulation: Mechanical Event Simulation with Linear Material Models Tutorial Mechanical Event Simulation with Nonlinear Material Models Tutorial Tutorial