Praveen Ahuja
Technical Manager - CAE HCL Technologies , Bangalore
By the End of this session, You will be able to : Understand and apply the Concept of FEM / FEA on Actual practical day-to-day / complex problems Understand Different Type of Analysis covered in FEA Prepare a suitable FE model for a given problem Know the Behavior of different type of FE Elements used , Concept of FE
Introduction to FEA
Methods to Solve Any Engineering Problem
Analytical Method
Classical Approach 100% Accurate Results Applicable only for Simple problems like Cantilever , simply supported beams and Cylinders etc.. Complete in itself
Numerical Method
Mathematical Approach Approximate, Assumptions Made Applicable to real life complicated problems
Experimental Method
Actual Measurement Time Consuming , Needs expensive setup Applicable only if physical prototype is available
Results can not be believed blindly and must be verified by experimental methods and Hand Calculations. Finite Element Method: Linear , Nonlinear , Buckling , Thermal, Dynamics & Fatigue analysis Boundary Element Method: Acoustics / NVH analysis Finite Volume Method: CFD (Computational Fluid Dynamics) & Computational Electromagnetic Finite Difference Method: Thermal & Fluid Flow analysis (in combination with FVM)
Results can not be believed blindly and Minimum 2 or more prototypes must be tested. -Strain Gauge - Photo elasticity - Vibration measurement (accelerometers) - Sensors for Temp & pressure etc - Fatigue test
Although applicable to simple shaped geometries only , Analytical methods are considered as Closed form solutions i.e. 100% Accurate
For a simple cantilever Beam, Governing equation is readily available , but this type of equations are not available for real life complex problems Basic Beam Bending equation is based upon many assumptions such as Small deflection , isotropic material , C/S of the beam remains plane and perpendicular to neural axis etc
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Is it possible to use all the above listed methods (FEA ,BEM , FVM, FDM) to solve same problem (say Cantilever problem)?
Answer : YES ! But the difference is in Accuracy achieved , programming ease and time required to obtain the solution
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etc.
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Aerospace Domain
Automotive Domain
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Hi-Tech /Electronics
Medical Devices
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Advantages of FEA
Visualization
Design Cycle time
No. of Prototypes
Testing
Design Optimization
FEA Computer Simulation allows multiple What-if scenarios to be studied quickly and effectively.
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Since it is very easy to measure the length of straight line. Measure the length of one line and multiply it by No. of lines to get the perimeter.
Approximate results.isnt it ?
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Physical System
FE Model
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Solution
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Fine Meshing and/or Higher order element yield more accurate results
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2D
Quadrilateral Element
Hexahedral Element
3D
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Post Processing
= K/M
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Type of analysis
Is it static or dynamic?
Are the loads applied gradually, or quickly? Vibrations? Seismic?
Linear or nonlinear?
Are there large deflections? Nonlinear materials? Contact?
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Is it really static?
Static analysis assumes that inertial and damping effects are negligible You can use time-dependency of loads as a way to choose between static and dynamic analysis.
If the loading is constant over a relatively long period of time, choose a static analysis.
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Nonlinearities in System
Geometric Non-linearity Large Deflection
Yield Point y
Unloading Plastic
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Materials
Material properties used will be approximate! Is the material homogenous (the same throughout)? Is it isotropic, orthotropic or anisotropic? Is temperature dependence important to the analysis? Is there rate or time dependence? Are composites used?
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Material Information
For linear isotropic material, need modulus of elasticity and Poissons ratio for a static analysis Need density for inertial loads For thermal analysis, need thermal conductivity Also need Coefficient of Thermal Expansion for thermal stress Need elastic plastic data for nonlinear materials
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Online:
Matweb: http://www.matweb.com Material Data Network: http://matdata.net/index.jsp
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Linear or Nonlinear?
If no stress-strain data is given, the program will assume the analysis is linear, and will use Youngs Modulus even if the part yields. This gives erroneous results when the loads cause the model to exceed yield.
Linear stress
Actual stress
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Units
Many general purpose FEA codes allow the user to enter a consistent unit set Make sure forces, displacements, material properties have same units these determine the units of the results.
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Mass unit Length unit Time unit Gravity const. Force unit Pressure/Modulus of Elasticity Density Unit Mod. Elasticity Steel Mod. Elasticity Concrete Density of Steel Density of Concrete
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Symmetry
Types of symmetry: Axisymmetry Rotational Planar or reflective Repetitive or translational
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Symmetry, Interrupted
Sometimes a small detail interrupts symmetry Can ignore it, or treat it as symmetric best to do a small test case if unsure
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Choice of elements
2D vs 3D vs line 2D elements are spatially 3D, but in the model they are geometrically 2D Element Order: linear, quadratic, polynomial Specialized elements? (composites, concrete, acoustics, coupled field) Geometric dimensionality-how the geometry is
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Evaluating Results
Stress criteria (Recall SoM Theory of Failures) Factor of safety Is stress greater than yield? Dont assume the results are correct! Are the displacements in the expected range? Compare to tests or theory, when possible Does the displaced shape make sense? Check reactions against applied loads
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Results Verification
Use deformed animation to check loads and look for cracks in model Combined load behavior is sometimes difficult to predict consider separating each load into its own load case to check
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Document Everything!
Detail all decisions made Explain simplifications Detail loads and supports Document material data Document test data Document as much results data as possible List reaction forces Stresses Displacements
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Having a fellow engineer review your analysis can help you catch problems in the model. Can be informal, one-on-one, or a formal review, with a team looking over the analysis. Either way, it's better to be embarrassed in front of your colleagues, than in front of your customer! (Garbage in ..Garbage Out !)
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Thanks !
Any Question ?
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