Finite Element Analysis

Praveen Patil

Y
Z

Contents

Introduction to the Finite Element Method

(FEM)
Future Trends

FEM Applied to Solid Mechanics Problems

Create elements
of the beam

Nodal displacement and forces

dxi 1

dyi 1

dxi 2

dyi 2

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
K is dependant upon Youngs
modulus and Poissons ratio,
as well as the geometry.
Equations from discrete elements
are assembled together to form
the global stiffness matrix.
Deflections are obtained by
solving the assembled set of
linear equations.
Stresses and strains are
calculated from the deflections.

Classification of Solid-Mechanics Problems

Analysis of solids
Static

Dynamics

Advanced

Elementary

Stress Stiffening

Behavior of Solids

Large Displacement
Geometric
Linear

Nonlinear

Instability

Fracture
Material

Plasticity
Viscoplasticity

Geometric
Classification of solids
Skeletal Systems
1D Elements
Trusses
Cables
Pipes

Plates and Shells

2D Elements

Solid Blocks
3D Elements

Plane Stress
Plane Strain
Axisymmetric
Plate Bending
Shells with flat elements
Shells with curved elements

Brick Elements
Tetrahedral Elements
General Elements

Governing Equation for Solid Mechanics Problems

Basic equation for a static analysis is as follows:
[K] {u} = {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

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 Galerkins 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.

Process Flow in a Typical FEM Analysis

Start

Problem
Definition

Analysis and
design decisions

Processor/Solver
Pre-processor
Reads or generates
nodes and elements
(e.g. MD-Patran)
Reads or generates
material property data.
Reads or generates
boundary conditions
(loads and
constraints.)

Step 1, Step 4

Generates
element shape
functions
Calculates master
element equations
Calculates
transformation
matrices
Maps element
equations into
global system
Assembles
element equations
Introduces
boundary
conditions
Performs solution
procedures

Post-processor
Prints or plots
contours of stress
components.
Prints or plots
contours of
displacements.
Evaluates and
prints error
bounds.

Step 6

Steps 2, 3, 5

Stop

Step 1: Discretization - Mesh Generation

surface model
airfoil geometry
(from CAD program e.g CATIA)

e.g. MD-Patran
ET,1,SOLID45
N,
1, 183.894081
N,
2, 183.893935
.
.
TYPE, 1
E,
1,
2, 80,
E,
2,
3, 81,
.
.
.

, -.770218637
, -.838009645

79,
80,

4,
5,

5,
6,

,
,

83,
84,

5.30522740
5.29452965

82
83

meshed model

Step 4: Boundary Conditions for a Solid Mechanics Problem

Displacements DOF constraints 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 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).

Step 4: Applying Boundary Conditions (Thermal Loads)

300
275

Nodes from
FE Modeler

275

250

250

225

Temp
mapper

225

200

200

175

Thermal
Soln Files

300

150
150
175

bf,
bf,
.
.
.
bf,
bf,

1,temp,
2,temp,

149.77
149.78

1637,temp,
1638,temp,

303.64
303.63

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

Z
Y

Information Available from Various Types of FEM Analysis

Static analysis
Deflection
Stresses
Strains
Forces
Energies
Dynamic analysis
Frequencies
Deflection (mode
shape)
Stresses
Strains
Forces
Energies

Heat transfer analysis

Temperature
Heat fluxes
Thermal gradients
Heat flow from
convection faces
Fluid analysis
Pressures
Gas temperatures
Convection coefficients
Velocities

Example FEM Application Areas

Automotive industry
Aerospace industry
Static analyses
Static analyses
Modal analyses
Modal analyses
Transient dynamics
Aerodynamics
Heat transfer
Transient dynamics
Mechanisms
Heat transfer
Fracture mechanics
Fracture mechanics
Metal forming
Creep and plasticity analyses
Crashworthiness
Composite materials
Aeroelasticity
Architectural
Metal forming
Soil mechanics
Crashworthiness
Rock mechanics
Hydraulics
Fracture mechanics
Hydroelasticity

Variety of FEM Solutions is Wide and Growing Wider

The FEM has been applied to a richly diverse array of scientific
and technological problems.
FEM is increasingly applied to a variety of real-world design and
analysis problems.

Technologies That Compete With the FEM

Other numerical solution methods:
Finite differences
Approximates the derivatives in the differential equation using
difference equations.
Useful for solving heat transfer and fluid mechanics problems.
Works well for two-dimensional regions with boundaries parallel
to the coordinate axes.
Cumbersome when regions have curved boundaries.
Weighted residual methods (not confined to a small subdomain):
Collocation
Subdomain
Least squares*
Galerkins method*
Variational Methods* (not confined to a small subdomain)
* Denotes a method that has been used to formulate finite element
solutions.

Technologies that Compete With the FEM (cont.)

Prototype Testing
Reliable. Well-understood.
Trusted by regulatory agencies (FAA, DOT, etc.)
Results are essential for calibration of simulation software.
Results are essential to verify modeled results from simulation.
Non destructive testing (NDT) is lowering costs of testing in
general.
Expensive, compared to simulation.
Time consuming.
Development programs that rely too much on testing are
increasingly less competitive in todays market.
Faster product development schedules are pressuring the quality of
development test efforts.
Data integrity is more difficult to maintain, compared to
simulation.

Contents

Introduction to the Finite Element Method

(FEM)
Future Trends

Future Trends in the FEM and Simulation

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. Future (?? Word excel??)
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 shellscripts and wizards.(??)

Conflicting Variables . . .with

Reduci

ng time

NVH & Crash Optimization of Vehicle Body Overnight

Ford body-in-prime (BIP) model of 390K DOF
MSC.Nastran for NVH, 30 design variables
RADIOSS for crash, 20 design variables
10 design variables in common
Sensitivity based Taylor approx. for NVH
Polynomial response surface for crash

Achieved overnight
BIP optimization on
SGI 2800/256, with
equivalent yield of 9
months CPU time

Future Trends in the FEM and Simulation (cont.)

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, 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.
FEM and simulation software available via Internet subscription.
Decreasing reliance on testing. But (??)

ng

Economics: Physical prototyping costs continue Increasi

Engineer more expensive than simulation tools
MSC/NASTRAN
Simulation Costs

Mainframes

1960
$30,000

2006
$0.02

Engineer
$36/hr

System
$1.5/hr

(Source: General Motors)

Cost of CAE
Simulation

(Source: Detroit Big3)

Cost of CAE
Engineer

Cost of Physical
Prototyping

1960

CAE Engineer
vs. System Costs

Workstations
and Servers

Years

2006

Thanks.