ME489: Finite Element Analysis in

Mechanical Design

Introduction:
Basics and Applications

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 1/104

 Presentation Outline
• Introduction to the Finite Element Method (FEM)
• Finite Elements: Types and Formulations
• Basic Steps in Using the FEM (an example from Solid Mechanics)
• FEA: Modeling, Errors, and Accuracy
• Responsibility of Users
• FEA Resources
• Future Trends
• Examples
• Tutorials
Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 2/104
 Finite Element Method Defined
✓ Many problems in engineering and applied science are governed by
differential or integral equations.

✓ The solutions to these equations would provide an exact, closed-form

solution to the particular problem being studied.

✓ However, complexities in the geometry, properties, and in boundary

conditions that are seen in most real-world problems usually mean that an
exact solution cannot be obtained or obtained in a reasonable amount of
time.
Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 3/104
 Finite Element Method Defined ……
✓ Current product design cycle times imply that engineers must obtain
design solutions in a ‘short’ amount of time.

✓ They are content to obtain approximate solutions that can be readily

obtained in a reasonable time frame, and with reasonable effort. The FEM
is one such approximate solution technique.

✓ The FEM is a numerical procedure for obtaining approximate solutions to

many of the problems encountered in engineering analysis

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 4/104

Finite Element Method Defined ……

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 5/104

 Finite Element Method Defined ……
• The basic concept of these methods is based on the idea of building a
complicated object with simple blocks, or, dividing a complicated object
into small and manageable pieces.

• Application of this simple idea can be found everywhere in everyday

life as well as in engineering.

• Examples:
• Lego (kids’ play)
• Buildings
• Approximation of the area of a circle
Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 6/104
Finite Element Method Defined ……
• Approximation of the area of a circle

• Area of one triangle:

“Element Si”
Si = R sin  i 1
2
2 

• Area of the circle:

N
S N =  Si = R N sin( ) 1
2
2 2
N ⎯→ R
⎯ 2
as N⎯
⎯→ 
i =1

• where N = total number of triangles ( elements)

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 7/104

 Origins of the Finite Element Method
• It is difficult to document the exact origin of the FEM, because the basic concepts
have evolved over a period of 150 or more years.

• The term finite element was first coined by Clough in 1960. In the early 1960s,
engineers used the method for approximate solution of problems in stress
analysis, fluid flow, heat transfer, and other areas.

• The first book on the FEM by Zienkiewicz and Chung was published in 1967.

• In the late 1960s and early 1970s, the FEM was applied to a wide variety of
engineering problems.
Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 8/104
 Origins of the Finite Element Method….
• The 1970s marked advances in mathematical treatments, including the
development of new elements, and convergence studies.

• Most commercial FEM software packages originated in the 1970s (ABAQUS,

ADINA, ANSYS, MARK, PAFEC) and 1980s (FENRIS, LARSTRAN ‘80, SESAM ‘80.)

• The FEM is one of the most important developments in computational methods

to occur in the 20th century. In just a few decades, the method has evolved
from one with applications in structural engineering to a widely utilized and
richly varied computational approach for many scientific and technological
areas.
Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 9/104
 How can FEM Help the Design Engineer
• The FEM offers many important advantages to the design engineer

• Easily applied to complex, irregular objects composed of several different

materials and having complex boundary conditions

• Applicable to steady-state, time-dependent, and eigenvalue problems

• Applicable to linear and nonlinear problems

• One method can solve a wide variety of problems, including problems in solid
mechanics, biomechanics, heat transfer, and acoustics, to name a few.
Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 10/104
 How can FEM Help the Design Engineer…
• General-purpose FEM software packages are available at a reasonable
cost, and can be readily executed on workstations and PCs

• The FEM can be coupled to CAD programs to facilitate solid modeling and
mesh generation

• Many FEM software packages feature GUI interfaces, auto-meshers,

sophisticated postprocessors, and graphics to speed the analysis and make
pre ad post-processing more user-friendly

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 11/104

 How can FEM Help Design Organizations?
• Simulation using the FEM also offers important business advantages to the
design organizations
• Reduced testing and redesign costs thereby shortening the product
development time
• Identify issues in designs before tooling is committed
• Refine components before dependencies to other components prohibit
changes
• Optimize performance before prototyping
• Discover design problems before litigation
• Allow more time for the designer to use engineering judgment

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 12/104

 Advantages of the Finite Element Method
• Can readily handle complex geometry:
• The heart and power of the FEM.

• Can handle complex analysis types:

• Vibration
• Transients
• Nonlinear
• Heat transfer
• Fluids
• Can handle complex loading:
• Node-based loading (point loads).
• Element-based loading (pressure, thermal, inertial forces).
• Time or frequency-dependent loading.
• Can handle complex restraints:
• Indeterminate structures can be analyzed.
Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 13/104
Advantages of the Finite Element Method…
• Can handle bodies comprised of nonhomogeneous materials:
• Every element in the model could be assigned a different set of material properties.
• Can handle bodies comprised of nonisotropic materials:
• Orthotropic
• Anisotropic
• Special material effects are handled:
• Temperature-dependent properties.
• Plasticity
• Creep
• Swelling
• Special geometric effects can be modeled:
• Large displacements.
• Large rotations.
• Contact (gap) condition.

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 14/104

Advantages of the Finite Element Method…
• Bodies composed of several different materials can be modeled:
• Element equations are evaluated individually.

• Alter the FE model relatively easily and cheaply.

• Corrective measures can be taken before any hardware is built

• Also the number of prototypes can be reduced.

• Physically meaningful to engineers and resemble actual structure.

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 15/104

 Disadvantages of the Finite Element Method
• A specific numerical result is obtained for a specific problem. A general closed-
form solution, which would permit one to examine system response to changes
in various parameters, is not produced.

• The FEM is applied to an approximation of the mathematical model of a system

(the source of so-called inherited errors.)

• Experience and judgment are needed in order to construct a good finite

element model.

• A powerful computer and reliable FEM software are essential.

• Input and output data may be large and tedious to prepare and interpret.
Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 16/104
Disadvantages of the Finite Element Method…
• Numerical problems:
• Computers only carry a finite number of significant digits.
• Round off and error accumulation.
• Susceptible to user-introduced modeling errors:
• Poor choice of element types.
• Distorted elements.
• Geometry not adequately modeled.
• Certain effects not automatically included:
• Buckling
• Large deflections and rotations.
• Material nonlinearities.
• Other nonlinearities.

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 17/104

Disadvantages of the Finite Element Method…
• Numerical problems:
• Computers only carry a finite number of significant digits.
• Round off and error accumulation.
• Susceptible to user-introduced modeling errors:
• Poor choice of element types.
• Distorted elements.
• Geometry not adequately modeled.
• Certain effects not automatically included:
• Buckling
• Large deflections and rotations.
• Material nonlinearities.
• Other nonlinearities.

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 18/104

Common Fields of Application
. Mechanical Engineering · Aerospace Engineering

· Civil Engineering · Automobile Engineering

· Electrical Engineering · Chemical Engineering

· Geomechanics · Biomechanics

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Information Available from Various Types of FEA
• Static analysis • Heat transfer analysis
• Deflection • Temperature
• Stresses • Heat fluxes
• Strains • Thermal gradients
• Forces • Heat flow from convection
• Energies faces

• Dynamic analysis • Fluid analysis

• Frequencies • Pressures
• Deflection (mode shape) • Gas temperatures
• Stresses • Convection coefficients
• Strains • Velocities
• Forces
• Energies
Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 20/104
Multi-Physics Applications
A. Structural
A1 Stress analysis
A2 Buckling
A3 Vibration analysis and others
B. Non-Structural
B1 Heat transfer
B2 Fluid flow
B3 Distribution of electric or magnetic potential
B4 Lubrication and others

• Examples of Multi-Physics Applications:

Thermal analysis: A + B1
Convective flow: B1 + B2
Manufacturing Processes: A+B1+B2
Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 21/104
Finite Elements: Types and Formulations
Finite Element Method:
• In contrast to the Finite Difference Method, FEM uses integral
formulations rather than difference equations to create a system of
algebraic equations
• Moreover, an approximate continuous function is assumed to represent
the solution for each element
• The complete solution is generated by connecting or assembling the
individual solutions, allowing for continuity at the inert-element
boundaries

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Finite Elements: Types and Formulations…

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 1D Elements

Example: bungee

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 2D Elements

(x,y)
(x,y)

Example: cloth
(x,y)

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 25/103

 3D Elements

(x,y,z)

(x,y,z)

Example: skin

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 26/103

 Finite Elements: Types and Formulations…
Element Formulation:
Spring Element
"Everything important is simple"

Two nodes: Node 1, Node 2

Local nodal displacements: dˆ1 x dˆ 2 x ( inch, m, mm )

Local nodal forces: fˆ1 x fˆ2 x (lb. Newton)

Spring constant (stiffness) k (lb/in, N/m, N/mm)

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 27/104

 Finite Elements: Types and Formulations…
Stiffness matrix

 fˆ1 x   k
ˆ =
 f 2 x   − k
− k   dˆ1 x 
 
k  dˆ 2 x 
 fˆ = kˆ dˆ 
(e ) (e ) (e )

© 2002 Brooks/Cole Publishing / Thomson Learning™

K  =    @ node 1, fˆ1x = −T = k dˆ1x − dˆ2 x ( )

N
Global stiffness matrix : kˆ ( e )
e =1

Global load vector : F  =  

N
fˆ ( e )  @ node 2, fˆ2 x = T = k dˆ2 x − dˆ1x ( )
e =1

 F = K d 
Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 28/104
 Classification of Solid Mechanics Problems

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 29/104

 FEM Applied to Solid Mechanics Problems
• A FEM model in solid mechanics can be thought of
as a system of assembled springs. When a load is
applied, all elements deform until all forces
balance.
• F = Kd
Create elements • K is dependent upon Young’s modulus and
of the beam
Poisson’s ratio, as well as the geometry.
• Equations from discrete elements are assembled
together to form the global stiffness matrix.
Nodal displacement and forces
dxi 1 dxi 2 • Deflections are obtained by solving the assembled
set of linear equations.
dyi 1 1 2
dyi 2
• Stresses and strains are calculated from the
4 3 deflections.
Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 30/104
 FEM Applied to Solid Mechanics Problems
2D model of a gear tooth showing nodes and elements
• FEA uses a complex system of points
called nodes, which make a grid called
mesh

• This mesh is programmed to contain

the material and structural properties
which define how the structure will
react to certain loading conditions

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 31/104

 FEM Applied to Solid Mechanics Problems
• Nodes are assigned at a certain density throughout the material depending
on the anticipated stress levels of a particular area. Regions that will
receive large amounts of stress usually have a higher node density than
those that experience little or no stress.
• The mesh acts like a spider web in that from each node. There extends a
mesh element o each of the adjacent nodes.
• The basic ingredients of any FEA of structural problem are:
• Geometry
• Material Model (Constitutive model)
• Loading
• Support or Boundary Conditions
Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 32/104
Governing Equation for Solid Mechanics Problems
Basic equation for static analysis is as follows:
{F} = {Fapp} + {Fth} + {Fpr} + {Fma} + {Fpl} + {Fcr} + {Fsw} + {Fld}
[K] = total stiffness matrix
{u} = nodal displacement
{Fapp} = applied nodal force load vector
{Fth} = applied element thermal load vector
{Fpr} = applied element pressure load vector
{Fma} = applied element body force vector
{Fpl} = element plastic strain load vector
{Fcr} = element creep strain load vector
{Fsw} = element swelling strain load vector
{Fld} = element large deflection load vector
Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 33/104
 Six Steps in the Finite Element Method
• Step 1 - Discretization: The problem domain is discretized into a collection of
simple shapes or elements.
• Step 2 - Develop Element Equations: Developed using the physics of the
problem, and typically Galerkin’s Method or variational principles.
• Step 3 - Assembly: The element equations for each element in the FEM mesh are
assembled into a set of global equations that model the properties of the entire
system.
• Step 4 - Application of Boundary Conditions: Solution cannot be obtained unless
boundary conditions are applied. They reflect the known values for certain
primary unknowns. Imposing the boundary conditions modifies the global
equations.
• Step 5 - Solve for Primary Unknowns: The modified global equations are solved
for the primary unknowns at the nodes.
• Step 6 - Calculate Derived Variables: Calculated using the nodal values of the
primary variables.

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 34/104

 Process Flow in a Typical FEM Analysis
Problem Analysis and
Start Stop
Definition design decisions

Processor Post-processor
Pre-processor
• Generates element shape • Prints or plots contours of
• Reads or generates nodes and functions stress components.
elements (ex: ANSYS) • Calculates master element • Prints or plots contours of
• Reads or generates material equations displacements.
property data. • Calculates transformation • Evaluates and prints error
• Reads or generates boundary matrices bounds.
conditions (loads and • Maps element equations
constraints.) into global system Step 6
• Assembles element
equations
Step 1, Step 4 • Introduces boundary
Steps 2, 3, 5
conditions
• Performs solution
procedures

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 35/104

 Step: 1: Discretization

surface model
airfoil geometry 2
3
4 5 11

1
12
14
13
(from CAD program)

mesh
generator

ET,1,SOLID45
N, 1, 183.894081 , -.770218637 , 5.30522740
N, 2, 183.893935 , -.838009645 , 5.29452965
.
.
TYPE, 1
E, 1, 2, 80, 79, 4, 5, 83, 82
E, 2, 3, 81, 80, 5, 6, 84, 83
.
.
.

meshed model
Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 36/104
 Step 4: Boundary Conditions

• Displacements  DOF constraints are usually specified at model boundaries

to define rigid supports.
• Forces and Moments  Concentrated loads on nodes usually specified on
the model exterior.
• Pressures  Surface loads are usually specified on the model exterior.
• Temperatures  Input at nodes to study the effect of thermal expansion or
contraction.
• Inertia Loads  Loads that affect the entire structure (ex: acceleration,
rotation).
Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 37/104
 Step 4: Boundary Conditions
300
Nodes from 300
FE Modeler 275
275
250
250 bf, 1,temp, 149.77
225 bf, 2,temp, 149.78
225 .
Temp 200 .
mapper 200 .
bf, 1637,temp, 303.64
175 bf, 1638,temp, 303.63

Thermal Soln
Files
150
150
175

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 38/104

Step 4: Applying Boundary Conditions (Other Loads)
• Speed, temperature, and hub fixity applied to sample problem.
• FE Modeler used to apply speed and hub constraint.

antype,static
omega,10400*3.1416/30
d,1,all,0,0,57,1

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 FEA: Modeling, Errors, and Accuracy
Outline of a FE analysis project

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 Sources of Error in the FEM
• The three main sources of error in a typical FEM solution are
discretization errors, formulation errors, and numerical errors.
• Discretization error results from transforming the physical system
(continuum) into a finite element model and can be related to modeling
the boundary shape, the boundary conditions, etc.

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 41/104

 Sources of Error in the FEM…
• Formulation error results from the use of elements that don't precisely
describe the behavior of the physical problem
• A particular element might be formulated on the assumption that
displacement vary linearly. Such an element will produce no formulation error
when it is used to model a linearly varying physical problem, but would create
a significant formulation error if it used to represent a quadratic or cubic
varying displacement field

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 42/104

 Sources of Error in the FEM…
• Numerical error occurs as a result of numerical calculation
procedures and includes truncation errors and round-off errors.

• Numerical error is therefore a problem mainly concerning the FEM

vendors and developers.

• The user can also contribute to the numerical accuracy, for

example, by specifying a physical quantity, say Young’s modulus, E,
to an inadequate number of decimal places.

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 43/104

 Responsibility of Users
• FE computer programs have become widely available, easier to use,
and can display results with attractive graphics. Even an inept user
can produce some kind of answer

• Any model, good or bad, can produce smooth and colorful stress
contours.

• It is possible that most FE analyses are so flawed that they cannot

be trusted.

• Even a poor mesh, inappropriate element types, incorrect loads, or

improper supports may produce results that appear reasonable on
casual inspection.
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 Responsibility of Users
• A responsible user must understand the physical nature of the problem
and the behavior of finite elements well enough to prepare a suitable
model and evaluate the quality of the results.
• Competence in using FE for stress analysis does not imply competence in
using FE for (say) magnetic field problems.
• The engineer who uses the software, not the software vendor, even if
the results are affected by the errors in the software, takes responsibility
for the results produced.

• USERS MUST HAVE A CERTAIN LEVEL OF BACKGROUND KNOWLEDGE

OF THE PROBLEM AS WELL AS TECHNIQUE BEFORE USING ANY FE
SOFTWARE

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 45/104

 Responsibility of Users
An Example:
Lateral midpoint displacement versus time for
a beam loaded by a pressure pulse. The
material is elastic-perfectly plastic. Plots were
generated by various users and various codes.

This example reminds us that any analysis

program is based on theory and
approximation, and may that a user may push
the program beyond its range of validity

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 46/104

 Commercially available FEA Software Suites
• Here we present a survey of some of the better-known integrated FEM
software packages. These integrated systems allow users to perform all
facets of FEM analysis, including modeling, meshing, solution and post-
processing.

• The Internet provides a vast new resource for individuals interested in the
FEM. See the Reference section of handouts for interesting FEM links to
start your Internet research.

• In addition to the integrated FEM packages, many vendors offer dedicated

software for solid modeling, mesh generation, FE equation generation and
solution, and post-processing.

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 47/104

 Partial List of finite element software packages
List of finite element software packages
• https://en.wikipedia.org/wiki/List_of_finite_element_software_packages

https://www.thomasnet.com/articles/top-suppliers/finite-
element-analysis-fea-companies/

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 48/104

Selected FEM Resources on the Internet
• Most commercial FEM developers have an extensive presence
on the Internet, with web pages that include company histories,
descriptions of software products, and example FEM solutions.

• Other good FEM resources on the web originate with academia,

government, and discussion and user groups.

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 49/104

 Future Trends
The FEM in particular, and simulation in general, are becoming integrated with the
entire product development process (rather than just another task in the product
development process):
– FEM cannot become the bottleneck.

• A broader range of people are using the FEM:

– Not just hard-core analysts.

• Increased data sharing between analysis data sources (CAD, testing, FEM
software, ERM software.)

• FEM software is becoming easier to use:

– Improved GUIs, automeshers.
– Increased use of sophisticated shell scripts and “wizards.”
Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 50/104
 Future Trends …
• Enhanced Multiphysics capabilities are coming:
– Coupling between numerous physical phenomena.
» Ex: Fluid-structural interaction is the most common example.
» Ex: Semiconductor circuits, EMI and thermal buildup vary with current densities.

• Improved life predictors, and improved service estimations.

• Increasing use of non-deterministic analysis and design methods:

– Statistical modeling of material properties, tolerances, and anticipated loads.
– Sensitivity analyses.
• Faster and more powerful computer hardware. Massively parallel processing.

•Decreasing reliance on testing.

• FEM and simulation software available via Internet subscription.

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 51/104
 Information Available from Various Types of
FEM Analysis

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 Example FEM Application Areas

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 Variety of FEM Solutions is Wide
and Growing Wider
• The FEM has been applied to a
richly diverse array of scientific
and technological problems.
• The next few slides present some
examples of the FEM applied to a
variety of real-world design and
analysis problems.

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 Finite Element Analysis
ANIMATIONS

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 55/104

 Hyperelasticity (boot seal 3D)
• Model is rubber boot with rigid shaft.
• Load step 1 is initial interference
• Load step 2 is downward pull, Load step 3 is rotation
• Half-symmetry model
• Bottom of boot is
constrained radially
and in UY direction
• Rigid shaft controlled
by pilot node located
on bottom

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Animation of Results

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Gasket Animation

Play External
Animation

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 Visco-Hyperelasticity (Pinch 3D)
• Model based on paper “On Large Strain Viscoelasticity: Continuum Formulation
and Finite Element Applications to Elastomeric Structures”, G. A. Holzapfel

• Example used is in 5.3 “Pinched thick-walled cylinder”

• 1/8 symmetry modeled
• Used different Ogden
foam constants (paper
defines long-term
moduli, but those
constants are used for
instantaneous moduli)
• Used rigid sphere
instead of rigid block
for compressing
cylinder

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 59/104

Animation of Results

Play External
Animation

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Transient Dynamic - With Hyperelasticity and
contact (Rubber ‘Donut’)
• Model is rubber ‘Donut’ surrounding a
flexible steel shaft and rigid ‘ground’
surface.

• Aim to find height of recoil of rubber ‘donut’

/ shaft assembly when forced into ground
and then released
• Load step 1 is initial displacement forcing
donut into ground (UY displacement)
• Load step 2 is release of donut (UY deleted)
• Ends of shaft restrained in (UX,UZ)

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 61/104

Animation of Results

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 Non-Linear Buckling
(Snap through of Soda can base)
• Model is the dome at the base of a
soda can

• Aim to find maximum pressure at

structural instability (Snap though) and
post buckling behaviour
• Arc Length (Riks) method analysis.
• Load step 1 Internal soda can is
pressurised. Load ramped.

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 63/104

Animation
of Results

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Axisymmetric Billet

Rigid Piece

Deformable Billet

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 Axisymmetric Billet ….

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 Axisymmetric Billet ….

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Axisymmetric Billet …

Resulting animation of hydrostatic pressure for fine mesh with symmetry expansion on.

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Blanking

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Chevron Crack in Extrusion

Dr. S. S Akhtar ME489_Topic01_1_FEA Introduction 70/104

Non-isothermal Cogging Simulation

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Crank Shaft Forging

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Extrusion Die Design

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Hot Extrusion

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Flair

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Hammer Forging

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Helical

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Heat Treatment of Gear

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Wire drawing

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 Resistance Spot Welding
Model Description: Spot Weld
• 2-D axisymmetric model (dimensions Location
per Fig.1 of Ref.1.).
• Thermal/Electric with PLANE67.
• Structural with PLANE42
• Thermal/Electric interface
resistances with TARGE169 Electrodes
and CONTA171.
• Nonlinear Material Properties are as
defined in Appendix A (derived from Steel plates
Tables 1 and 2 of Ref.1). to be welded
• Refer to Ref.3 for APDL input to build and
run model.

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 Resistance Spot Welding
Results(Cont’d):
Animation of temperature vs time

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Solid modeling and finite element meshing for the billet
and die arrangement of the extrusion die

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 Animation of Deformation Process
Die-1 2D Animation

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Die-3 3D Animation

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 1-10 1-10 1-10

Experiment: DMZ and metal flow pattern; same die; same ram speed; 3 different materials: Al-6063, aluminum, and lead

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 Crash Analysis: Train video

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 Crash Analysis: Train side view

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 Crash Analysis: Train angle view

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 Metal forming: Door panel

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 Drop Test: Cellular phone

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 Disc Brake

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 Metal Cutting

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 Laser processes: Heat transfer and
thermal stresses

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 SPECIAL ASSIGNMENT # 1

• LOOK AT DIFFERENT THINGS AROUND YOU.

1. MAKE A LIST OF ANY FIVE THINGS WHERE, IN YOUR OPINION, FINITE

ELEMENT ANALYSIS WILL BE USEFUL.

2. IDENTIFY ONE WHERE FEA WILL BE MOST USEFUL. GIVE A ONE-LINE REASON.

3. SUBMIT ON TUESDAY (Jan 16, 2024)

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