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Why FEA ?
Modern mechanical design involves complicated shapes, sometimes made of different materials that as a whole cannot be solved by existing mathematical tools. Engineers need the FEA to evaluate their designs
Ken Youssefi
Ken Youssefi
By the early 70's, FEA was limited to expensive mainframe computers generally owned by the aeronautics, automotive, defense, and nuclear industries. Since the rapid decline in the cost of computers and the phenomenal increase in computing power, FEA has been developed to an incredible precision.
Ken Youssefi Mechanical Engineering Dept
Finite element analysis starts with an approximation of the region of interest into a number of meshes (2D or 3D elements). Each mesh is connected to associated nodes (black dots) and thus becomes a finite element.
Node
Element
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Strain
Mechanical Engineering Dept
Stress
Stress & Strain relationship
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Partial derivatives
Reaction forces
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Ken Youssefi
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Calculations: 2a = 40 a1 = 40, a2 = 0, a3 = 0 b1 = - 4, b2 = 4, b3 = 0
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c1 = -10, c2 = 0, c3 = 10
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Example
40 0
40 0
Change of notations
1 = (1)U1
2 = -(1/10)U1 + (1/10)U3 3 = -(1/4) U1+ (1/4) U5 1 = (1)U2 2 = -(1/10)U2 + (1/10) U4 3 = -(1/4) U2+ (1/4) U6
Ken Youssefi Mechanical Engineering Dept
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Example
Substitute and to obtain displacements u and v for element 1.
1 = (1)U1 2 = -(1/10)U1 + (1/10)U3 3 = -(1/4) U1+ (1/4) U5 1 = (1)U2 2 = -(1/10)U2 + (1/10) U4 3 = -(1/4) U2+ (1/4) U6
u = 1 + 2 x + 3 y v = 1 + 2 x + 3 y
Calculation:
u1 = U1 + [-1/10 (U1) + (1/10) U3] x + [-(1/4) U1+ (1/4) U5 ] y v1 = U2 + [-1/10 (U2) + (1/10) U4] x + [-(1/4) U2+ (1/4) U6 ] y
Ken Youssefi Mechanical Engineering Dept
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Example
Rewriting the equations in the matrix form, u1 = U1 + [-1/10 (U1) + (1/10) U3] x + [-(1/4) U1+ (1/4) U5 ] y v1 = U2 + [-1/10 (U2) + (1/10) U4] x + [-(1/4) U2+ (1/4) U6 ] y
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Example
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Example
The next step is to determine the strains using 2D strain-
displacement relations,
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Example
Differentiate the displacement equation to obtain the strain
u1 = U1 + [-1/10(U1) + (1/10) U3] x + [-(1/4) U1+ (1/4) U5 ] y v1 = U2 + [-1/10(U2) + (1/10) U4] x + [-(1/4) U2+ (1/4) U6 ] y
1st element
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Example
Element 2 2nd element
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3D Element
yx yz zy zx
z
xy
xy
Second subscript indicates the positive direction of the shear stress
xz
x
x Due to equilibrium condition;
xy = yx zx = xz zy = yz
State of Stress
Three dimensional stress matrix
x 0 , y = 0 , z = 0
x = (x / E ), y = - x ,
z = - x
Using the three dimensional (triaxial state of stress) stress strain relations for homogeneous, isotropic material and plane-stress,
x = (x / E ) - (y) - (z) = (x / E ) - (y / E ) - (z / E )
y = ( y / E ) - ( x ) - ( z ) = ( y / E ) - ( x / E ) - ( z / E ) z = (z / E ) - (x) - (y) = (z / E ) - (x / E ) - (y / E )
Stresses in terms of strains
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Shear stress xy = xy G
E G= 2(1 + )
Matrix form
3 - (x + y) 2 + (x y - xy) = 0
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Displacement
Strain
Stress
Stress & Strain relationship
Partial derivatives
Material
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(max )component > ( )obtained from a tension test at the yield point
= Sy
Failure
=
= Sy
Sy 2 To avoid failure
Sy
2
max =
=Sy
Sy 2n
n = Safety factor
Design equation
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t
(Sy)h >> (Sy)t
h h h
t
(total strain energy) (strain energy due to hydrostatic stress) = strain energy due to angular distortion > strain energy obtained from a tension test at the yield point failure
Ken Youssefi Mechanical Engineering Dept
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<
Sy
< Sy
Sy n
Design equation
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Perform two tests, one in compression and one in tension, draw the Mohrs circles for both tests. 2 1 Sut
Suc
Stress state
Tension test
Compression test
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Failure envelope The component is safe if the state of stress falls inside the 1 > 2 and 3 = 0 failure envelope.
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2 or 3
Sut
Safe Safe
2 or 3
Sut
Sut
Suc -Sut
Safe
1
-Sut
I
II III
Sut
Safe
Suc
Suc
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2
Sut
1 = n
Sut
Design equation
Sut
II
-Sut
Zone II
1 > 0 , 2 < 0 and 2 < Sut
III
Sut
-Suc
1 = n
Design equation
Zone III
1 > 0 , 2 < 0 and 2 > Sut
Ken Youssefi Mechanical Engineering Dept.,
1 (
1 Sut
1 Suc )
2
Suc
1 n
Design equation
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T = [x y z xy yz zx ]
and the corresponding stresses
T = [x y z xy yz zx ]
The goal is to calculate displacement, strains, and stresses from the given external forces.
Ken Youssefi Mechanical Engineering Dept
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f B Body forces (forces distributed over the volume of the body: (gravitational forces, inertia, or magnetic)
f S surface forces (pressure of one body on another, or hydrostatic pressure) f i Concentrated external forces
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V dV =
T
Internal work
U f dV +
Work done by body forces
f dS +
iT
The left side represents the internal virtual work done, and the right side represents the external work done by the actual forces as they go through the virtual displacement. The above equation is used to generate finite element equations. And by approximating the object as an assemblage of discrete finite elements, these elements are interconnected at nodal points Us denotes the displacement due to surface forces Ui denotes the displacement due to point forces
Ken Youssefi Mechanical Engineering Dept
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The displacement at any point measured with respect to a local coordinate system for an element are assumed to be a function of the displacement at the nodes.
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Matrix form
C (m) is the elasticity matrix of element m and I(m) are the elements initial stresses. The elasticity matrix relates strains to stress.
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Strain-displacement matrix
Elasticity matrix
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where
B(m) Represents the rows of the strain displacement matrix C(m) Elasticity matrix of element m H(m) Displacement interpolation matrix U Vector of the three global displacement components at all nodes F Vector of the external concentrated forces applied to the nodes
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The above equation describes the static equilibrium problem. K is the stiffness matrix.
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y x dx
dA = y dx
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y=4-
4 x 10 44
Example
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Example
Calculating the stiffness matrix for element 2.
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Example
The stiffness of the structure as a whole is obtained by combing the two matrices, K = K1 +K2
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Example
KU = R
The load vector R, equals Rc because only concentrated loads act on the nodes.
R=
where Py is the known external force and F1x, F1y, F3x, and F3y are the unknown reaction forces at the supports.
Ken Youssefi Mechanical Engineering Dept
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Example
The following matrix equation can be solved for nodal point displacements
KU = R
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Example
The solution can be obtained by applying the boundary conditions
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Example
The equation can be divided into two parts,
The first equation can be solved for the unknown nodal displacements, U3, U4, U7, and U8. And substituting these values into the second equation to obtain unknown reaction forces, F1x, F1y, F3x, and F3y
Once the nodal displacements have been obtained, the strains and stresses can be calculated.
Ken Youssefi Mechanical Engineering Dept
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FEA Pre-Processing
Mesh Mesh is your way of communicating geometry to the solver, the accuracy of the solution is primarily dependent on the quality of the mesh. The better the mesh looks, the more accurate the solution is.
A good-looking mesh should have well-shaped elements (proportional), and the transition between densities should be smooth and gradual without skinny, distorted elements.
Ken Youssefi Mechanical Engineering Dept
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FEA Pre-Processing
The mesh elements supported by most finite-element codes:
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Entire length of a modeled component can be captured with a single element. This member can transmit axial loads only and can be defined simply by a material and cross sectional area.
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A quadrilateral mesh is usually more accurate than a mesh of similar density based on triangles. Triangles are acceptable in regions of gradual transitions.
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Tetrahedral (tet) mesh is the only generally accepted means to fill a volume, used as automesh element by many FEA codes.
Ken Youssefi Mechanical Engineering Dept
10-node Quadratic
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2nd order tetrahedral coarse mesh 2st order tetrahedral fine mesh
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CAD models prepared without consideration of FEA needs. Analytical geometry developed by or for analyst for sole purpose of FEA. CAD models prepared by the design group for eventual FEA. CAD models unsuitable for use in analysis due to the amount of rework required.
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Clean geometry
geometrical features must not prevent the mesh from being created. The model should not include buried features.
Parent-child relationships
parametric modeling allows defining features off other CAD features.
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Fillet across shallow angle Sliver surface caused by a slightly undersized fillet
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Outside corner breaks or rounds. Small inside fillets far from areas of interest. Screw threads or spline features unless they are specifically being studied. Small holes and slots outside the load path. Decorative or identification features. Large sections of geometry that are essentially decoupled from the behavior of interested section.
Ken Youssefi Mechanical Engineering Dept
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Holes removed
Fillet removed
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Try to use the same CAD system for all components in design. When the above is not possible, translate geometry through kernel based tools such as ACIS or Parasolids. Using standards based (IGES, DXF, or VDA) translations may lead to problem. Visually inspect the quality of imported geometry. Avoid modification of the imported geometry in a second CAD system.
Use the original geometry for analysis. If not possible, use a translation directly from the original model.
Ken Youssefi Mechanical Engineering Dept
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FEA Pre-Processing
Material Properties
The only material properties that are generally required by an isotropic, linear static FEA are: Youngs modulus (E), Poissons ratio (v), shear modulus (G), and yield strength (or ultimate strength). Strength is needed if the program provides safety factor or performance result.
G = E / 2(1+v)
Provide only two of the three properties. Thermal expansion and simulation analysis require coefficient of thermal expansion, conductivity and specific heat values.
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FEA Pre-Processing
Nonlinear Material Properties
A multi-linear model requires the input of stress-strain data pairs to essentially communicate the stress-strain curve from testing to the FE model Highly deformable, low stiffness, incompressible materials, such as rubber and other synthetic elastomers require distortional and volumetric constants or a more complete set of tensile, compressive, and shear force versus stretch curve.
A creep analysis requires time and temperature dependent creep properties. Plastic parts are extremely sensitive to this phenomenon
Ken Youssefi Mechanical Engineering Dept
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FEA Pre-Processing
Comments If you are selecting the property set from the codes library, be aware of the assumptions made with this selection. Their properties hold constant throughout the assigned entity. Average values are used (variation could be up to 15%).
Localized changes due to heat or other processing effects are not accounted for.
Any impurities present in the parent material are neglected.
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FEA Pre-Processing
Boundary Conditions (Loads and Constraints)
In FEA, the name of the game is boundary condition, that is calculating the load and figuring out constraints that each component experiences in its working environment.
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Boundary Conditions
Loads Loads are used to represent inputs to the system. They can be in the forms of forces, moments (torque), pressures, temperature, or accelerations. Constraints Constraints are used as reactions to the applied loads. Constraints can resist translational or rotational deformation induced by applied loads.
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Boundary Conditions
Linear Static Analysis
Boundary conditions are assumed constant from application to final deformation of system and all loads are applied gradually to their full magnitude.
Dynamic Analysis
The boundary conditions (Loads) vary with time.
Non-linear Analysis
The orientation and distribution of the boundary conditions vary as displacement of the structure is calculated.
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Boundary Conditions
Degrees of Freedom
Spatial DOFs refer to the three translational and three rotational modes of displacement that are possible for any part in 3D space. A constraint scheme must remove all six DOFs for the analysis to run. Elemental DOFs refer to the ability of each element to transmit or react to a load. The boundary condition cannot load or constrain a DOF that is not supported by the element to which it is applied.
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Boundary Conditions
Constraints and their geometric equivalent in classic beam calculation.
Fixed support
Pin support
Roller support
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Boundary Conditions
A solid face should always have at least three points in contact with the rest of the structure. A solid element should never be constrained by less than three points and only translational DOFs must be fixed.
Accuracy
The choice of boundary conditions has a direct impact on the overall accuracy of the model. Over-constrained model an overly stiff model due to poorly applied constraints.
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Patch 4
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Patch 2
Patch 3 Patch 4
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Fixed legs
Stress
Displacement Displacement
Stress Displacement
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Displ. = .016 mm
Displ. = .06 mm
Displ. = .02 mm
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Stress=11.6x107 N/m2
Stress=5.8x107 N/m2
Stress=10.4x107 N/m2
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Summary of Pre-Processing
Build the geometry (CAD model for FEA) Prepare the model for meshing (simplify) Create the finite-element mesh Add boundary conditions; loads and constraints Select material or provide properties Specify analysis type (static or dynamic, linear or non-linear, thermal, etc.)
These activities are called finite element modeling.
Ken Youssefi Mechanical Engineering Dept
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Stress
Max stress (von Mises) = 43.9 MPa Sy = 96.5 MPa (Al 2014)
Set gap to 5 in. Fix the back plate Design requirements Safety factor between 2.0-2.5 and deflection less than 2 mm
Mesh Quality
The ideal shape of a tetrahedral element is a regular tetrahedron with the aspect ratio of 1. Analogously, an equilateral triangle is the ideal shape for a shell element.
Sometimes, Irregular tetrahedral are created by the program. These distorted elements have high aspect ratio. An aspect ratio that is too high causes element degeneration, which in turn affects the quality of the results.
Aspect Ratio
Right click the Mesh icon and select Create Mesh Plot
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Post-Processing
No
View Displacement Fringe Plot Are magnitudes in line with your expectations? No
Yes
View Stress Fringe Plot Is the quality and mag. of stresses acceptable?
Yes
No
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Last Comment
Finite Element Analysis makes a good engineer great