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30/12/2014 NAFEMSProceduralBenchmarksForCommonFabricationDetailengineeringanalysisandsimulationFEA,FiniteElementAnalysis,CFD,Comput

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30/12/2014 NAFEMSProceduralBenchmarksForCommonFabricationDetailengineeringanalysisandsimulationFEA,FiniteElementAnalysis,CFD,Comput

ProceduralBenchmarksForCommon
FabricationDetail
AsummaryreportoftheFENetEducationandDissemination
(E&D)workshopinMajorca,Spain,25thMarch2004.
ByDr.JimWood,UniversityofStrathclyde,UK
ThisarticleprovidesasummaryoftheobservationsmadeattheEducationand
DisseminationsessioninMajorca,whichwasreasonablywellattendedand
resultedin34hoursofstimulatingdiscussion.
Thethreeproceduralbenchmarksareshownbelow.
Resultsobtainedfromallcontributorsareavailablefordownloadforeach
benchmark,aswellasresultsandthebenchmarksthemselves.Thefollowing
observationsarebasedontheresultscontainedinthesespreadsheetsandalsofrom
themorecomprehensivesubmissionsmadebyparticipants.

Fig.1ProceduralBenchmarkFENET_E&D1ShellIntersection
BenchmarkDownload(PDF)
ResultsDownload(PDF)
LocalStresses
Stiffness,Overall,Field
PresentationDownload(PDF)

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30/12/2014 NAFEMSProceduralBenchmarksForCommonFabricationDetailengineeringanalysisandsimulationFEA,FiniteElementAnalysis,CFD,Comput

Fig2ProceduralBenchmarkFENET_E&D2Shell
Reinforcement
BenchmarkDownload(PDF)
ResultsDownload(PDF)
LocalStresses
FieldStresses
Stiffness&OverallStresses
PresentationDownload(PDF)

Fig.3ProceduralBenchmarkFENET_E&D3OffsetShellMid
surface
BenchmarkDownload(PDF)
ResultsDownload(PDF)
LocalStresses
Stiffness,Overall&FieldStresses
PresentationDownload(PDF)

Genericobservations
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30/12/2014 NAFEMSProceduralBenchmarksForCommonFabricationDetailengineeringanalysisandsimulationFEA,FiniteElementAnalysis,CFD,Comput

1.Significantvariationinthemodelling,results,assessmentandconclusionsrelatingtofitnessfor
purposeofsuchdetailisapparentacrossanalystsandindustrysectors,forbothstaticandfatigue
situations.
2.Humanerrorisapparent,including:
a.Misinterpretationofboundaryconditions
b.Incorrectuseoffiniteelementfunctionalitythatalteredphysicalresponse
c.Reportingwrongresults
d.Usingstressoutputdirectlyatsingularities
e.Usingaveragedstressesatshellintersections.
3.Lackofengineeringcommonsenseisapparent.Forexample,notallcontributorscheckedthatthe
fieldstressescomparedwellwithhandcalculations,whereappropriate.
4.Fromthislimitedlinearelasticexercise:
a.Theneedforfiniteelementknowledgeisconfirmed
b.Theneedforgeneralengineeringeducationisconfirmed
c.Theneedforindustryspecificknowledgeisconfirmed
d.Theneedforvalidationisconfirmed
e.TheneedforadequateQAproceduresisalsoconfirmed.
5.Establishedcommonbestpracticeacrossthevariousindustrysectorsisnotapparent.
6.Variousguidelinesexistforweldmodellingandassessmentinfewindustrysectors.
7.Useofexperimentallyderivedresultsonrealweldgeometriesisrecognisedasanecessarypartofthe
assessmentprocessforfatigue.ItishowFEAresultsareobtained(oftenatlocationswheresingularities
exist)thatprovidesvariationsinapproach.
8.Aswithallanalyses,theadequacyofanyidealisationmustbejudgedintermsofthepurposeofthe
analysisbeingconducted.Theidealisationofsuchfabricationdetailwillaffectstaticandfatigue(and
dynamic,buckling,limitandfractureassessments)todifferentdegrees.
9.Theinfluenceoffabricationdetailcanbelocalorglobalinnatureandthisfactshouldbeconsidered
whenjudgingadequacy.Thedetailsselectedforconsiderationasproceduralbenchmarkshaveboth
localandglobalmeasuresselectedastargetsandallshowedvariation.
10.Itispossibletouseshellmodelstoobtainnecessarystressdataforfatigueassessmentofsuchdetails,
butcareandunderstandingisnecessary.Itshouldalsoberecognisedthatshellmodelswillproducefinite
convergedresultsatintersections.
11.Therewouldappeartobetwodistinctapproachestoobtaininghotspotstressesfromfiniteelement
models:
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30/12/2014 NAFEMSProceduralBenchmarksForCommonFabricationDetailengineeringanalysisandsimulationFEA,FiniteElementAnalysis,CFD,Comput

a.Astresslinearizationprocedure(notrequiredwithshellrepresentations),designedtoremove
thepeakstresscomponentandleavethemembraneandbendingstresscomponents.Suchan
approachwillincludegrossgeometricstressconcentrationeffects.Somefiniteelementsystems
providepostprocessingtoolsfordefiningtheassessmentsectioninboth2Dand3D
representationsandforlinearisingtheresults.ThisapproachiscommoninthePressureVessel
industry.
b.Anumberofextrapolationapproaches,withslightvariationsintheextrapolationprocedures,
areinuse.Theseapproachesinvariablyinvolveelementsizesoftheorderof0.4tanddifferin
whetherlinearorquadraticextrapolationisusedtothehotspotlocation(whichisoftena
singularityinnonshellmodels).Someoftheseproceduresalsoprovidedetailsofhowthestress
distributionsfromshellmodelsshouldbedisplacedbyuptohalfashellthickness(dependingon
theangleoftheintersection),beforeextrapolatingtothehotspot.However,itisrecognisedthat
specificCodesofPracticemaynotgivetheanalystanychoiceinwhichproceduretoadopt.
12.Somefatigueassessmentproceduresrequiretheuseofthestressrangeontheweldthroatarea.
Stressesplottedacrossthethroatwillshowahighlynonlinearvariation.Althoughnotalwaysclear,itis
likelythatanaveragevalueofstressisrequiredfromtheresults,toprovideconsistencywithhand
calculations.Althoughnotalwaysclear,itislikelythatasimplemembrane+bendingvalueofstress,
withpeakcomponentremoved,isrequiredfromtheresults,toprovideconsistencywithhand
calculations.
13.Someanalystsusedthickshellelements.Thefactthatmostdidnot,wouldperhapsindicatethat
participantsfromdifferentdisciplinesdonothaveacommonunderstandingofwhenplatesandshells
becomethick.
14.GiventhenatureoftheDisplacementFiniteElementMethodandthedetailsexamined,itisperhaps
notsurprisingthatgreatestagreementisapparentforglobalstiffness(asmeasuredbyoverall
displacements),closelyfollowedbyfieldstresses(bydefinitionawayfromlocalstressconcentrations).
Greatestvariationisapparentforlocalstresses,whichincludefinitevaluesderivedfromdistributionsin
thevicinityofsingularities.Inaddition,aswouldbeexpected,greatestvariationisapparentforvery
smalltargetvalues,withbestagreementgenerallyforlargevalues.

PreliminaryobservationsforE&D1
1.Forthisdetail,thepracticeofdisplacingshell
stressdistributionsbyhalfashellwallthickness
beforeinterpolatingvaluesatthenotional
positionofweldtoes(hotspot),wouldseem
unnecessary.
2.ThevariousresultsprovidedbyAnalyst
Identifier1showremarkablylittlevariation
amongst2DAxiandshellmodels(withand
withoutweldrepresentation).Whilstinclusionof
theweldstiffness(bywhatevermeans)improves
thecomparisonwiththehighlyrefined2DAxi
results,itisnotapparentthatthisadditionalcomplexityismeritedoverasimpleshellrepresentationand
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30/12/2014 NAFEMSProceduralBenchmarksForCommonFabricationDetailengineeringanalysisandsimulationFEA,FiniteElementAnalysis,CFD,Comput

useofstressesatthelocationcorrespondingtotheweldtoe.
3.Althoughnotconsideredinthesebenchmarks,itisnotedthatasimpleshellintersectionrepresentation
alreadyhastoomuchmass,withouttheadditionofanymeasuresdesignedtoincludetheeffectofthe
weld.Thiswillhavesomebearingondynamicanalysesandweldmodelswillresultinagreaterneedto
reducethedensityoflocalelementsforaccuraterepresentation.

PreliminaryobservationsforE&D2
1.Thereasonforthelargevariation
incontactradiusresultsforload
case2isnotapparent.Thisis
clearlyafunctionofglobalstiffness
representationaswellasthe
effectivenessofthecontactmethods
used.Giventherelativelygood
agreementonoveralldeflectionsin
mostcases,itmustbeassumedthat
thedifferencesarelargelyduetothe
contactmethods.Thisfact
emphasisestheneedforadequatecontactbenchmarks.
2.ThevariousresultsprovidedbyAnalystIdentifier1showremarkablylittlevariationamongstDAxi
andshellmodelsfordeflections,fieldstressesandweldtoestresses,forloadcase1.Thepoor
comparisonsforloadcase2areduetothelackofcontactsimulationintheshellmodelforloadcase2.
3.Assumingthereinforcingplatetobeintegraldidnotprovidegoodagreementforfieldstressesatthe
platecentre.Thecomparisonoflocalstressesintheregionoftheweldarereasonable,particularlyfor
thoseoflargermagnitude.Itiscleartherefore,thatifsuchanassumptionistobemade,thencaremust
betakentoensurethatbothplateseffectivelyactasonethroughuseofasuitablenumberofspotor
puddlewelds.Theresultsforthecentralspotweldidealisation,wouldindicatethatanintegral
behaviourmaybepossiblewithrelativelyfewplateconnections.
4.Neglectingtheoffsetduetothereinforcingplateandassumingadoublethicknessintegral
representationoverthereinforcedareaproducedsimilarresultstotheintegralidealisationwithoffset.

PreliminaryobservationsforE&D3
1.Onlytwoparticipantsshowed
thattheproblemwaslarge
displacement(subsequently
confirmedbythecoordinator),in
spiteofthetipdeflectionbeingless
thanthethicknessoftheplate.
Reductionsindeflectionsand
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stressesaresignificant.Therulesofthumbcommonlyusedasaguidetowhenlargedisplacementeffects
becomesignificantforbeams,platesandshellsareclearlynotapplicableforthisproblem.Thereasonfor
thisisapparentwhenthesourceofthenonlinearityisgivendueconsideration.
2.3Dmodels(shellsandbricks)showvariationsinresultsacrossthewidth,whichareobviouslyabsent
from2Dresults.Notallcontributorscommentedonthiseffect.
3.Neglectingtheoffset,evenwithcorrectplatethicknesses,failstopredictadequatevaluesforoverall
stiffness,fieldstressesandlocalstresses.Analystsshouldthereforethinkcarefullybeforeneglecting
offsetsinplate/shellmidsurfaces,astheireffectscanhaveaglobalnatureaswellaslocal.Forthinner
plates/shells,largedisplacementeffectsmayacttoreducetheglobaleffectoftheoffset,throughlocal
bendingofthejointandeffectiverealignmentofthemidsurfaces.
4.Themodellingofcontactbetweenthelappedplatesappearsirrelevantfortherelativejointsizes
considered.Theresultsforseparateplates,withandwithoutcontact,andmodelswheretheplateswere
assumedintegralappearsimilar.Thelattermodelhowever,failstopickupthestresssingularitythat
existsateitherendofthelaprunningbetweenfilletweldroots.Almostallcontributorsfailedtohighlight
thissingularity,inanymodel.

Closure
Thegeneralconsensusofthoseparticipatingwasthatthiswasaworthwhileexercise,thatshouldbeof
interesttothewiderFEcommunity.Giventhelevelofparticipation,thisfactwasclearlynotalways
recognised.Itshouldberecognisedthattherelevanceofthegeneralobservationsclearlyhavebroad
interesttotheentirefiniteelementcommunity,itshouldalsoberecognisedthattherelevanceofthe
detailofthemodellingstrategiesusedisnotconfinedtothoseinvolvedinwelding15mmthicksteel
plate!Itisnowmytasktotryandpulltogethersomesortofconclusionsfromthisexercise.Tothisend,I
haveaskedcontributorstohavealookatthefinalcollatedresultsandtaketheopportunitytocomment
ontheresultsthattheyprovidedinrelationtotherest.Inaddition,theyhavealsobeenaskedtohavea
lookatthepreliminaryobservationsandtocommentontheseandaddtheirownifnecessary.
Onreceiptofeveryonescomments,Iwillthendocumenttheexercise.Thefinaldocumentislikelyto
consistofseveralparts.AnIntroductionprovidingthebackgroundandaimsoftheprojectthe
ProceduralBenchmarkSpecificationstheRoundRobinresults(withanonymitymaintained)
observationsfromtheexerciseandfinallysomeconclusionsregardinggoodandbadpracticeinthe
analysisandassessmentofsuchdetails.
Thisfinalreportisnowavailabletodownload,aswellasbeingavailablefromNAFEMSinhard
copyformat.
ThedownloadisavailableinaloresPDFformat(1.8MB),aswellasahiresformat,inazipped
package(22MB).
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