A PAPER PRESENTATION ON

FINITE ELEMENT METHOD

Design Optimization of Mini Baja Frame

FOR

EUREKA-JIDNYASA 2K9
ORGANISED BY,

Tatyasaheb Kore Institute of Engineering and Technology, Warananagar.

HELD BY, Department of Mechanical Engineering, T.K.I.E.T., Warananagar. 1 SUBMITTED BY, Mr. Digvijay D. Patil. BE Mech. RIT, SAKHARALE.
patil.digvijay@yahoo.co.in Mobile: 9766666871.

Abstract:
Think. A Super Computer Analysis Model of a component. There is no prototype of any component now. This will be possible because of the Miracle made by the emerging technology and tremendous revolution in the analysis techniques. One of these techniques is nothing but the Finite Element Method. Before 1950s the designs of the components, elements, parts or shapes of a system were not implicating Finite Element Method. The engineers, scientists were not able to specify where the design will fail and what will be the exact values of the stress & strain. They were totally dependent on Trial & Error Method or Update Solve Update Method. The replacement of any component before its failure or to manufacture a component, which will sustain given loading conditions, it was required to have a definite method to get correct solutions of the problems. But, when in 1950s the Finite Element Method was introduced in engineering application, it started giving almost accurate results. The growth of this technique is attributed to rapid advances in computer technology, particularly over last decade. The Finite Element Method is becoming an extremely sophisticated tool in engineering application due to its computerization. This method is widely accepted in many branches

of industries. Due to closeness towards exact solutions, the Finite Element Method is yet not challenged or paralleled by any other Numerical Method.

INDEX

Sr. No.
Abstract

Title

Page No. 2 4 7

1. 2.

Introduction Finite Element Method

Setup the Field Variable Discretization Approximation Functions Gradients of the Unknown Quantity and Constitution of Relationships Elemental Equations Global Equations Solve Equations & Solutions

3. 4.

Computerization of Finite Element Method CASE STUDY: Design Optimization of Mini Baja Frame (Mini Baja Roll Cage)

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5. 6. 7. 8. 9. 10.

Finite Element Software Analysis of Frame Advantages of FEM Disadvantages of FEM Future with FEM Conclusion References

14 17 17 18 18 19

1. Introduction
What is a Numerical Method?
Numerical Method is the mathematical technique used to enumerate the approximate results for the given problem. There are several numerical methods. The most important among them are, 1. Finite Difference Method 2. Finite Element Method 3. Boundary Element Method 4. Finite Volume Method

What is Finite Element Method?

The Finite Element Method is a technique used to derive an approximate solution of any complex engineering problem that can be reached by subdividing the problem into smaller, more manageable elements i.e. finite elements. The behavior of the structure can be easily predicted by solving linear equations sets in the form of matrix algebra for those finite elements. The finite element method was introduced in 1950s and has become an engineering tool applied to various problems which yield approximate results. The problems includes the complexities dealing with, 1. Geometry 2. Boundary Conditions 3. Loading Conditions

In mechanical problems the elements may be model membranes, beams, plates, solids, fluids etc. This method contains conversion of the available component data into matrices & interpolating differential equations and their processings.

There are main three types of problems that can be analyzed by FEM.

Table 1
Sr. No. Problem Engineering Area Aerospace Steady 1. State Problem Automobiles Application Stress analysis of aircraft frames, Wings etc. Stress analysis of camshafts, cylinder blocks, chassis, connecting rods etc. Civil Stress analysis of Dams, walls, bridges, etc. Aerospace 2. Eigen Value Problem Automobile Frequency components, blades.etc. Frequency analysis of gearbox casing and body shell etc. Automobile Time dependent analysis of engine piston 3. Transient Problems Civil Mechanical Analysis of impact problems & dynamic crack propagation Structural structures stress waves in rock analysis of engine rotor

helicopter

Finite element is an approximating numerical method. So, obviously it is having errors. The magnitude of the error depends on, 1. Type of Model 2. Size of the Model 3. Fitness of the Model

Why Finite Element Method?

The Finite Element Method is being used in almost every engineering discipline like automotives, biomedical, electronics, electrical, manufacturing, designing, civil etc. It also can provide platform to heat mass transfer, dynamics, radiations problems. Finite element method optimizes new designs, verifies fitness of existing designs, predicts performance & evaluates new concept. In addition to this, FEM is also taking applications in accident analysis, reconstruction and forensic investigation.

Why we use Stress Engineering?

The Stress Engineering is a leading provider of finite element analysis service to the industries. There is lot of difference in engineering knowledge and industrial or practical experience. The Stress Engineering crashes the band gap between knowledge and experience by acting as a connecting link in association with Finite Element Method.

2. Finite Element Method (FEM)

When the Finite Element Method is applied to a problem, following tasks are performed in step-by-step manner. 1. Setup the Field Variable: The field variable is the governing variable and deals with the unknown things which are to be evaluated. E.g. In structural problems, displacement is field variable and in thermal problem, temperature is the field variable. 2. Discretization: The points at which the primary unknowns are required to be evaluated are called nodes or nodal nodal points, lines (or The and interfaces between the elements are called nodal/planes/ number of surfaces).
Cross Section of the DAM

unknowns at a node is termed as Nodal degree of freedom (DOF). The most appropriate

element type is chosen for the analysis required. The total number of elements used and their variation in size and type within a given body are primarily matters of engineering judgment.
Discretization of the DAM

One

may

choose

one

dimensional (1-D), two dimensional (2-D), three dimensional (3-D) or an axisymmetric

element depending upon the physical system under consideration. The axisymmetric elements are constructed by rotating a 2-D finite element about the axis of symmetry by 360. The discretization is the most important step in this method because, the accuracy of the result depends on the details of the discretization and 90% of the time is spent in this phase of analysis. It needs sound engineering knowledge and understanding of physics of the problem to get meaningful results. 3. Approximation Functions: This step involves choosing a pattern or shape for the distribution of the unknown quantity within each element. The unknown quantity can be displacement for stress-strain analysis, temperature in heat flow problems, fluid pressure or velocity for fluid flow problems. The approximation function is defined within the element using the nodal values of the element. Linear, quadratic and cubic polynomials are the frequently used functions. For an n-node element the approximation function can be expressed as, u = N1u1 + N2u2 + + Nnun Where, u1, u2un are the nodal unknowns and N1, N2Nn are the shape functions. 4. Gradients of the Unknown Quantity and constitution of Relationships: These relationships are necessary for deriving the equations for each finite element. E.g. In stress analysis problems, gradients and constitutive relationships are simply the strain displacement and the stress-strain expressions respectively. Strain/displacement: x = du/dx Stress-strain: x = E x (Hookes Law)

Where, x = Strain in x direction, x = Stress in x direction, E = Modulus of elasticity. 5. Elemental Equations: In this step, equations governing the behavior of a generic (typical) finite element are obtained by invoking available laws and principles. These equations describe a relationship between the nodal DOF and the nodal forcing parameters for the generic element. This relationship can be written in compact matrix form.

[K e] { e} = {f e} [K e] = element property matrix, { e} = element vector of unknown DOF, {f e} = vector of element nodal forcing parameters 6. Global Equations: Repeated application of the generic element equation, results in the element equations for other elements. Then the element equations are added together using method of superposition to obtain global or total equations for the entire body. The process of superposition is called assembling. This relationship can be written in compact matrix form as, [K] {} = {F} [K] = assembled (global) property matrix, {} = assembled (global) vector of nodal unknown, {F} = assembled (global) vector of element nodal forcing parameters To evaluate the performance of the body, it is needed to impose boundary conditions on it. Boundary conditions are the physical constrains or the supports that exist on the body. 7. Solve Equations & Solutions: The assembled equations are then solved for the s by using gauss elimination or iterative method. s are called primary unknowns because these are the first quantities derived by FEM. After deriving primary unknowns are derived. These can be stresses, strains and forces etc. in structural problems or velocity & discharge in fluid problems. The derived primary and secondary unknowns are the solutions of the problem. The results are then interpreted in the tabular form or graphically represented. This simplifies the understanding of the problems and helps in design decisions.

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3. Computerization of Finite Element Method

The tremendous inventions and advancements in computer science & information technology, it is assured the effective use of Finite Element Method to solve the problems. The popular softwares based on FEM are,

Table 2
Software
Ansys V 11.0 NASTRAN NISA ALGOR STAD PRO GT-STUDEL

Area of Application
Structural, Heat, Electrical Aerospace, Automobile Structural Stress Analysis Civil Structural

In these softwares, the finite element method is stored as embedded programs. These programs cant be modified or altered. The computer user is able to decide the input parameters, discretization and nodal numbering. After giving all the required input data the CPU processes matrix operations as that in FEM to get the solution. The output of the problem can be displayed on the monitor screen. e.g. the output can be in the form of nodal displacement, force value or deflection, stress value etc. in case of the structural problems. This process is done with the help of following important parts of FEM softwares.

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Preprocessors:
The preprocessor is used to develop the finite element model. There are two methods in preprocessors to generate element mesh.

User should define individual nodes, elements and build the mesh manually. A solid model of the component is designed in the CAD software. It is then imported into the FEM software and the computer generates the mesh automatically by auto mesh option.

The mesh is nothing but discretization of the component into element continuum. The preprocessor requires following direct user input data. 1. Coordinate system: For flexible model generation, it is required to define the coordinate system. Different coordinate systems like Cartesian, cylindrical, spherical systems are available for global and local coordinate systems allowing flexible model generation. The local coordinate system defines the origin in any position with respect to component. E.g. defining an arc is simpler in spherical and cylindrical system than Cartesian system. 2. Nodes & Elements: Once the node has been defined it is easy to define a row of nodes by intermeeting the coordinates. When nodes are generated, they are used to define the elements. The numbering of the elements starts from the first node. The mesh tool in the FEM software is so powerful that it can generate 2-D or 3-D meshes very quickly. 3. Geometrical & Material Constants: This input data is fed to the computer by the user. The geometrical constants include thickness of model, area, second moment of inertia of the component. The Material constants are, Youngs Modulus, Poissons Ratio.

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4. Loads: In order to get correct solutions of the problem, it is necessary to define the load on the model correctly. The loads can be body force, pressure, thermal force etc. The gravitational force is considered to be absent for easy calculations. The loads are generally defined at the nodes of the element. 5. Meshing: When the component model is ready with nodal numberings and loadings, it is meshed by mesh tool in the software. The mesh size can be controlled manually or it can be auto meshed. The preprocessor converts the local coordinates into global coordinate system and also perform necessary analytical calculations of higher order matrices that will take a lot of time for human approach with the help of solution tool.

Postprocessors:
After deriving the output data it is arranged into tabular form by postprocessor. In case of structural problems, the nodal displacements & stress values at nodal points are given in the tabular form. The graphical solutions can also be obtained in the form of graphs by plot control tool in the FEM software. The output also contains the deformed shapes of the analyzed model with different colors representing different stress values at different locations of the components. The maximum stresses are denoted by red color, medium stresses by yellow or green color and minimum stresses by blue color. Thus, we can easily come to know where the failure is most likely to occur.

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4. Design Optimization of Mini Baja Frame (Roll Cage):

The purpose of the drivers roll cage in Mini Baja is to prevent the driver who is wearing a restraint system from being crushed or seriously injured in the event of an impact or a rollover. The cage must be large enough for the drivers comfort and should provide safety supports to the driver. The main components of the frame are, Rear Roll Hoop (RRH), Roll Hoop Overhead members (RHO), Lower Frame Side members (LFS), Side Impact members (SIM) & Front Bracing members (FBM).

5. Finite Element Software Analysis of Frame:

There are a few features of the design that may need some additional strengthening. For this reason it is deemed that there should be an analysis of front impact and side impact
The Components of Roll Cage (Frame)

(Major Impacts) by loading the frame for those kinds of the load. However, before these analyses are performed the loading forces exerted on the vehicle must be completely defined. With the help of softwares, the stress distribution is
Stress Pattern Band

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defined ranging from maximum to minimum values. Different stress values bear different colors for easy distinguishing. The maximum stress is represented by red color and minimum by blue color. 1. Front Impact: Front Impact is assumed to occur when the worst case of collision happens by running the vehicle into a stationary object. To validate this load the analysis is done using the

Front Impact Stress Distribution (Enlarged View)

maximum speed of the vehicle and the target impact force is used to find the resulting crash pulse, or deceleration time. In this case a deceleration of 10 Gs is the assumed loading. This is equivalent to a 7500 lbf load on the vehicle. The analysis figure shows that the high stresses are induced in the highlighted beam or link element. Then the frame can be predicted to fail at the corners and centre of the red highlighted element. Now suppose, if we add two links
Front Impact Stress DistributionAfter Modification (Enlarged View)

symmetrically & in diagonal direction, the

Front Bracing Modification

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stress concentration is greatly reduced. So, this strategy is acceptable. 2. Side Impact:

Side Impact Stress Distribution Side Impact Stress Distribution Bracing Modification (Enlarged Side View) After Modification (Enlarged View)

Side impact is most likely to occur with the vehicle being hit by another Mini Baja vehicle running on its neighbouring side. To validate this load the analysis is done using the target impact force of 5G or 3750 lbf, to find the resulting stress distribution. To reduce stress concentration we can add two more links to convert it into structure so that it will sustain the load. This modification increases the strength of the Lateral Cage of the Mini Baja Frame.

Real World Testing Results:

In real world testing or practical experience, we came to know that, front and side loading were causing maximum stress region i.e. forecasting the region of failure. When we modified the designs by addition of component links, the failure regions were almost eliminated as discussed above.

Case Study Conclusion:

The usage of Finite Element Method (or FEA) is valuable to design the Mini Baja Frame through Software package. The analysis allowed addition of four important components to withstand Front and Side impacts. The Finite Element Method gave a very accurate

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prediction of where the failure will occur. In practical phenomenon, at the same position, the Mini Baja Frame was subjected to fail. So, results were almost matching.

6. Advantages of FEM:
FEMs biggest advantage is versatility. A variety of problems with complicated geometries, material properties and boundary conditions can be solved readily by FEM.

Many General Purpose Finite Element Software Packages (e.g. Ansys) are available to perform different types of analyses and to reduce the analytical time for the computation of unknown quantities. These softwares touch several field of problems like stress analysis, heat transfer, electromagnetic field analyses etc.

It is relatively easy to control accuracy. Accuracy can be increased by refining the Finite Element Mesh or choosing more fine Elements or by employing higher order elements.

7. Disadvantages of FEM:

Exact solutions cant be achieved by FEM. The solutions show at least some error with the exact readings as they are approximately determined.

Numerical solution is obtained at one time for a specific problem only. Experience : Sound Engineering judgment and some understanding regarding physics of the problem are required in creating the Finite Element Model. Poor selection of the Element type or poor Finite Element Discretization can lead to disastrous results.

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8. Future with FEM:

The whole world considers Finite Element Method to be the future. Finite Element Method is important because, it is relatively easy to tackle, relatively easy to computerize and relatively faster than other methods. It can also offer the financial rewards by omitting the use of prototype and doing the analysis on the component design on the computers. It is an approach and science oriented towards applications. Finite Element Method touches so many aspect of our life. For simplicity we can divide the field into three major activities: Structural Analysis, Heat Transfer Analysis and Electromagnetic Analysis. Needless to say they all interact. This will become quite simpler to get along with FEM. The Finite Element Method is one of the best tools in engineering used for analysis purpose and it can be surely said that, it will show a rapid revolution and faster growth of engineering stream.

9. Conclusion:
The Finite Element Method can be considered as the connecting link between Practical (Industrial) and Theoretical Knowledge. Practical Knowledge is the knowledge gained by the experiences in the industry and Theoretical Knowledge is the knowledge achieved in the learning phase. In Finite Element Method, we are trying partially to predict the natural behavior of the components. The Finite Element Method being on a large numbers of applications will carry major role in the Human Development and Better Sanitation.

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The miracle of Finite Element Method holds a strong promise of its presence in the field of every engineering aspect. Not only in mechanical but it is ready to get applied in almost every field including electronics, instrumentation, mechanical etc.

10. References:
Books:
1.

Finite Element Method : Theory and Practice By : Mr. M. J. Fagan.

University of Hull.

2.

Introduction to Finite Elements in Engineering By : Mr. Chandrapatala and Mr. Belegundu.

Journals:
1.

Introduction to Finite Element Method By : Tai Hun Kwon. Technical Design Report on Mini Baja Vehicle Design Optimization By : Mr. Jonathan Hastie and Prof. Has hemi.
Year : December 2005. Department of Mechanical, Industrial and Manufacturing Engineering & College of Engineering, Northeastern University, Boston.

2.

3.

Finite-element method By : W. Robert J. Funnel.

Department of Biomedical Engineering, McGill University. Year : 2005.

4.

SAE International Journals

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Internet Sources:
1. 2. 3. 4. www.engineering.uiowa.edu/~uisae www.BajaBuggyBaja450ccOffRoadMiniBajaBuggyS2SPowersports.com.htm www.wolfram.com www.google.co.in (Journals and Books Section)

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