IE360: CAD/CAM
Computer Aided Design and
Computer Aided Manufacturing
Lecture 8: Finite Element Analysis
Outline
➢ Introduction
➢ FEA Method
➢ Mesh Generation
➢ Cautions
Objectives
•To identify the importance and uses of finite
element analysis.
•To recognise the steps of applying finite element
analysis.
•To distinguish different types of elements and
boundary conditions.
c n al l
OV
Introduction:
➢ Finite Element Analysis (FEA) is a numerical method of
solving engineering problems.
➢ FEA have been successfully applied in (discussion will be
limited to structural problems):
▪ Structural analysis
▪ Heat transfer,
▪ Fluid flow,
▪Magnetic field analysis,
▪Etc.
a
loading
Effigy It
Videos for FEA
• https://www.youtube.com/watch?v=geUCv
KayhHE
• https://www.youtube.com/watch?v=fmKKF
kREu8Q&list=PL4XCKfOBgSSdde5BE5T
5WzCXvLzQgTyNN
➢ Why FEA?
▪ Used in problems where analytical solution not easily
obtained.
▪ Mathematical expressions required for solution not simple
because of complex:
• geometries
• loadings
• material properties
▪ Costly experimental procedures.
➢ FEA: Basic concept
▪ Divide body into finite number of simpler units called
elements.
▪ Elements connected at nodal points.
• points common to two or more
adjacent elements.
• set of elements referred to as “mesh”.
•The process of dividing the object into
elements is called discretization.
Discretization
Schematic illustration of a finite element model, depicting the
discretization of the object into a collection of elements and
nodes, along with the associated boundary conditions.
2 427 22 Rolled
1g
x i
f Fixed
Rx o
➢ Examples of FEA Mesh is shown in the following figure
➢ FEA vs. analytical methods
▪ Analytical methods involve solving for entire system in
one operation.
▪ FEA involves defining equations for each element and
combining to obtain system solution.
• is therefore an approximation technique.
control
ad v6
qFEA Method: era
➢ The most common technique is
free
Displacement Method
▪ Loads are known.
▪ Resistance to deformation of elements known.
▪ Displacements are unknown values.
➢ Solve for displacements
▪ Stress is a secondary solution, derived from
displacements.
➢ Structural FEA
▪ Structural problems defined in terms of:
• loads (forces)
• resistance to deformation (stiffness)
• displacements
▪ Given by: [k]{d} = {F}
• k = stiffness, d = displacement, F = force
➢ FEA concept
▪ Assume that variation of displacement across element is
a simple function.
▪ Results in a set of relationships for displacement at
nodal points for each element.
▪ Combine for entire mesh.
• problem is converted to large number of simple algebraic
equations.
➢ Spring element displacement
I
➢ Computer use in FEA
▪ Because of
• the relatively simple nature of equations,
• connectivity between elements (resultants from adjacent
elements applied),
• combining of solutions for individual elements,
• large number of equations to solve.
▪ FEA is well suited to computational automation.
➢ FEA steps:
▪ Three steps:
• pre-processing
• analysis
• post-processing
➢ Pre-processing
▪ Requires definition of:
• system geometry (e.g. solid modelling)
• material properties
• restraints on the system (boundary conditions)
• loads applied
• meshing
• type and properties of elements
➢ Older systems
▪ Prior to use of GUIs (graphic user interfaces)
• analyst would define input by hand.
• each nodal location, element type, constraint, etc. will be
input one at a time to a data file.
➢ Use of solid modeling in FEA
▪ Solid modeling use simplifies and enhances FEA.
▪ Model database is used as pre-processor input e.g. a model
from CATIA.
▪ May permit definition of all preprocessing data.
➢ Modern solid modeling systems
▪ Allow direct definition of element type.
▪ Have automatic mesh generators.
▪ Permit definition of loads and boundary conditions
graphically, directly upon model geometry.
▪ Allow specification of other data through menu input.
Automated mesh generation:
➢ Mesh shape considerations
▪ Shape of mesh critical to analysis.
▪ Higher density improves solution at cost of computational time.
▪ Simple geometry requires fewer elements, more complexity
requires increased density.
▪ Mesh shape related to loads, and boundary conditions.
coarse Time
Low mesh density Higher mesh density
➢ Auto meshing exists for 2D and 3D systems.
➢ Intelligent meshing systems consider geometry and topology
of model.
➢ Some systems support bi-directional associativity.
➢ Changes in model geometry will produce changes in mesh.
➢ However, changes in topology (additional edges) would
require remeshing.
➢ Different mesh cases may be defined for the same model.
➢ Early analysis may involve coarse mesh.
▪ Low mesh density.
▪ Faster computation time.
➢ Mesh is refined for further analysis.
Refined mesh
Simulation of
Brinell hardness
test
➢ Model cases
▪ In addition to mesh cases
• Load cases,
• Material cases
• Constraint cases, may be defined.
▪ As with meshes, early analysis may involve simplified
loading and constraints, later refined.
➢ Boundary conditions and loads
▪ Much of specification is automated.
▪ Specification not limited to nodes only.
▪ Possible to specify restrains and loads for high level geometric
entities (edges, faces).
▪Pre-processing within CAD package
➢ Automated mesh generation concerns:
▪ Mesh shape should consider loads and restraints.
▪ Automated systems may NOT do so.
▪ This can be of high concern when defining meshes for
different load cases.
➢ Element Types:
▪ 1D (Dimensional elements)
▪ 2 D (area elements)
▪ 3 D (volume elements)
➢ Load cases (mechanical): Rules of thumb
▪ Moments
• apply at single node, apply at nodes on an edge
▪ Point forces:
• apply to single node, nodes along edges, nodes on
surface.
▪ Surface pressure: N um
• may be uniform or non-uniform.
• applied to edge or surface.
➢ Post-processing
▪ Output of FEA data.
▪ Desire simplicity for speed in design evaluation.
▪ Many systems support enhanced graphics display.
➢ Output Examples
▪ Extreme values reported in list form.
▪ Extreme values displayed in color on rendered solid
model.
• typically include color index.
▪ Note that max value occur at surface unless internal loads
present.
➢ Design evaluation
▪ Von Mises stress
▪ Tresca stress
▪ Principle stress
Stress analysis outputs
➢ Design evaluation
▪ Von Mises stress
▪ Tresca stress
▪ Principle stress
D
stress
Stress analysis outputs
Cautions:
▪ Results only as good as the job done in creating mesh,
applying loads, materials and boundary conditions.
• if not calculated and applied correctly, results of little use.
▪ Must understand
• mechanics principles.
• material and physical properties.
▪ Mesh generation is often a critical aspect.
▪ Proper mesh can reduce errors in primary results (such as
displacements) by half.
▪Boundary conditions are the most difficult item to define.
▪ Point loads produce inaccurate local deformation.
