507 - An Introduction To FEA Via Solid Edge and FEMAP - Mark Sherman

An Introduction to FEA via Solid
Edge and FEMAP

Mark Sherman
Siemens PLM Software
FEMAP
#SEU12
Introduction
Mark Sherman
sherman.mark@siemens.com
610-458-6502
BS Aerospace and Ocean Engineering
Virginia Tech
Boeing Helicopter
GE Astro Space
Joined FEMAP (Enterprise Software
Products, Inc. 1992 )
Page 2
Siemens AG 2012. All Rights Reserved.

FEMAP History
Founded by George Rudy, 1985
Mission PC-based dedicated Pre- and

Post-Processor for Engineering Finite
Element Analysis
Originally a Pre-Processor Only for

MSC/PAL and MSC/NASTRAN on 64k RAM
IBM PCDOS to Windows Transition 19901992
Rapid Growth from 1992 on
Significant strength in Aerospace

accounts
Laboratory Module of the ISS (Boeing)
OEM Partnership MSC/Nastran for

Windows
Tens of thousands of licenses worldwide
Page 3

FEMAP
Continuous development with the

same core team!
Since 1985 there have been more than 30 releases of FEMAP with
only one major architecture change (DOS to Windows)
FEMAP Development Team is all engineers turned programmers

FEA By Engineers for Engineers
Product development has been driven by FEA Analyst input
Page 4

Why use Finite Element Analysis

Understand the behavior of engineered parts and assemblies
Structural Behavior
Static Stress, Deflection, Load Distribution - Linear
Dynamic
Natural Frequency Normal Modes
Frequency Response (Sinusoidal) Accel., Disp., Stresses
Transient Response (General Time-Varying Loads) Accel., Disp.
Stresses
Non-Linear
Contact
Geometric Nonlinearity
Material Nonlinearity
Thermal
Steady-State
Transient
Page 5

Quality
Material Cost
Weight
Reduce requirement for physical testing
Maximize these benefits - Important to integrate FEA into the Design

Process
Page 6

Customer Success Stories - Duracast

Customer was driven to seek a CAE solution
Rising cost of materials need to optimize their current designs to save
material use and cost (use petroleum based products)
To reduce the level of physical prototyping to save time and cost
Maintain integrity of product advanced solutions required including nonlinear
analysis
A single seat of FEMAP with NX/Nastran
saves this company hundreds of thousands
of dollars per year in material cost
Page 7

Space Exploration Technologies

Launch Vehicle Developer
Challenge: Develop rockets that
reduce the cost of space access by a
factor of 10
Approach: Create virtual mockups of
entire rockets using Femap and NX
software
Results: More effective collaboration
between design groups, and a 50%
productivity improvement helped
successfully launch two Falcon 1
rockets
"On the analysis front Femap and

NX Nastran were the clear
winners, not only due to wide
industry acceptance but also from
an ease of use and support
standpoint.
Chris Thompson, vice president of
Development Operations
Page 8

A Brief History of FEA and FEM

The concept of a Finite Element was introduced by Prof. R.W. Clough of UC
Berkeley in 1960 at an ASCE Conference.
NASTRAN (NASA STRuctural ANalysis) was developed for NASA by a consortium
of several companies for the analysis of the Saturn V rocket.
Siemens PLM Software acquired MSC.Nastran source code in 2003 and has
greatly improved the performance and capabilities of
NX Nastran through the latest release of NX Nastran 8.1
Finite Element Modelers(Pre/Post Processors), the tools used to generate Finite
Element meshes and view results, were first commercialized in the 1970s.
Siemens PLM Software began the first commercial offering of FEM software with
the introduction of SDRC SuperTab in the 1970s.
Siemens continues to support the analysis community with Femap and NX CAE
pre/post-processors.
Page 9

The Solution
Consider a single degree of freedom system a simple spring:
Apply the following conditions to generate a system of simultaneous equations
where displacements are the unknowns:
Equilibrium of forces and moments
Strain- displacement relations
Ku=P
(static analysis)
Stress-strain relations
K: spring stiffness
P: applied load
u: displacement
Page 10

Solution for Multiple DOFs

Any real structure can be modeled as a collection of elements connected
at nodes
With many elements and nodal dofs, a matrix approach to the solution is
adopted
ka
Element stiffness matrix

k11 k12
ka =
kb
2
k21 k22
All element matrices are assembled into a global stiffness matrix
Kgg =
Page 11
ka11
ka12
ka21
ka22 + kb22
kb23
kb32
kb33
Modeling of Real Structures

The behavior of the real structure is obtained by considering the collective
behavior of the discrete elements.
The user is responsible for the subdivision or discretization of real-world
structures.
Element choice has significant influence on the behavior
A graphic preprocessor such as FEMAP/SE Simulation is the key tool for
generating a model that accurately simulates real world structures
Kgg =
ka
-ka
-ka
ka + kb
-kb
-kb
kb
Contributions from all other elements
nxn
Page 12


Structural Behavior
Static Stress, Deflection, Load Distribution - Linear
Dynamic
Frequency Response (Sinusoidal)
Transient Response (General Time-Varying Loads)
Non-Linear
Contact
Thermal
Steady-State
Transient
Page 13

Linear Static Analysis
90%+ of all FEA projects
100% Linear if you double the loads,

you get double the response
Material stays in the elastic range

return to original shape
Small Deformation
Maximum Displacement much smaller
than characteristic dimensions of the
part being studied, i.e. displacement
much less than the thickness of the
part
Loads are applied slow and

gradually, i.e. not Dynamic or Shock
Loading
Page 14

FEA Building Blocks
Numerous Element Types
This makes it possible to accurately model

the real-world performance of your
engineered structure
Element selection helps balance model size
vs.
Solution accuracy
Hardware resources
Solution time
Results interpretation time
Another consideration for solids is time to

mesh the model if a hex mesh is desired
Page 15

Element Basics
Choose elements to represent the real structure behavior
Rod Element: Axial and Torsion Stiffness only (pin connected truss)
Beam : Classic Euler-Bernoulli Beam depending on property options used
Shear effects, shear center offset, etc can be included, user must understand the
defaults and options to ensure proper behavior is included
Plate/Shell : Started with Kirchhoff and Mindlin theories but now many different
tweaks and modifications included to improve accuracy.
When elements of different types connect, user must be aware of potential
compatibility problems and use special modeling techniques as needed.
Examples: beams connecting normal to plates, plates connecting to solids
Page 16

Finite Elements 0D
Scalar Elements
Springs
Node to node axial or torsional
Dampers
Node to node axial or torsional
Mass
Point masses can be used to represent additional mass and inertia in the structure
that is non-structural or where modeling detail is not required
Rigid Elements
Can be used to represent rigid connections within the model
Page 17

17
Finite Elements 1D
Line Elements
Rod
Uniaxial tension compression and
torsion no bending or shear loads
Used to model pin-ended truss
structures
Bar/Beam
A regular beam that carries axial,
torsion, bending and shear loads
Very versatile offsets and tapers can

be included
Page 18

18
Finite Elements 2D
Plate and Shell Elements

Used to represent thin structures like
sheet metal structures.
Additional features for shear-only,
membrane-only, composite laminate
etc.
Quad4 / Tria3
Isoparametric 3/4 noded
triangular/quadrilateral
Quad8 / Tria6
Higher order isoparametric 6/8 noded
triangular/quadrilateral
Page 19

19
Finite Elements 3D
Solid Elements
Used to fill and model solid volumes
Hexa
Regular hexahedral elements
Penta
Pentrahedral used to mesh transitions
Tetra
Tetrahedral elements can be generated fully
automatically on solids
Page 20

20
Linear Static Analysis
What can you expect to learn from a

linear static Finite Element Analysis
Displacements
Load Paths
Stress
Page 21

Linear Static Analysis Modeling Guidelines
Use the
Displacements
Load Paths
Stress
Page 22

Important Guidelines
Linear Analysis is small displacement, small angle theory
Must use nonlinear analysis if the displacement changes the stiffness or loads
Pressure loads on flat surfaces, have no membrane component unless nonlinear large
displacement solution performed.(load carried by bending stiffness only)
Linear contact is a misnomer, contact condition is iterative solution, but no other nonlinear
effects are considered.
Mesh density required is a function of the desired answers

Must have enough nodes so model can deform smoothly like the real structure.
In general, accurate stresses require more elements than accurate
displacements.
Goal is for a small stress gradient across any individual element

Normal modes should always be run before any dynamic solution
Confirm model behavior, stiffness and mass properties are correct
Page 23

Important Guidelines
Finite Element Analysis is an Approximate Solution to a Complicated
Problem :
Therefore, Sound Engineering Judgment is Required
Our Answers are only as good as the assumptions we make
Common sources for analysis uncertainty:
Numerical round off (usually small)
FEM : mesh density, element formulation, element connections
Boundary conditions
Loads and environments seen by the structure
Page 24

Linear Statics - Stresses

To accurately recover stresses in shell and solid elements, the mesh must
be very dense in areas of high stress gradients
Stress Changing Too

Fast Across One Element
Page 25

Stresses from the Web
Page 26


To accurately recover stresses in shell and solid elements, the mesh must
be very dense in areas of high stress gradients
Stress Changing Less Across

an Element More Accurate
Page 27


Keeping Model Size Reasonable
Increase the Mesh Density where you need it, decrease it where you dont
Page 28

Page 29

Guidelines for Good Stress Interpretation Singularities
Page 30

Guidelines for Linear Static Analysis - Stresses
Remember the limitations of Linear analysis
Increase Mesh Density in High Stress Regions
Ignore Stress Answers at Singularities
Zero Radius Fillets
Inside Corners
Loaded and Constrained Nodes
Page 31

When you need FEMAP

Monaco Coach
Solid Mesh Impractical
Shells alone, not enough
Beam Lumped Mass required
Transient Dynamic Analysis a
requirement
Courtesy of Predictive Engineering
Page 32

Real FEA - Examples

Bechtel River Project
Solid Mesh Impractical
Shells alone, not enough
Beam Rigid, and Lumped Mass required
Transient Dynamic Analysis a requirement
Post-processing Data Processing Required
Page 33

Real FEA - Examples
Boeing - International Space Station

Laboratory Module
Page 34

Real FEA - Examples

Why cant we just tetra-mesh this?
Just this little section is 565,405 Nodes 275,558 Elements and theres
only one element through the thickness
Full Model would be billions
Page 35

SE Simulation FEMAP
Model Size Limitations when one has to idealize a structure beyond
the Solid, Shell and Beam Elements available in SE Simulation
Modeling Limitations
Composite Laminates
Nonlinear Geometry - Large
Displacements
Nonlinear Materials - outside
the elastic range, or non-elastic
materials (rubber).
Time or Temperature Dependent Loading

Specialty Elements like CBUSH where you can have displacement
dependent stiffness and damping
CWELD - CFAST
Page 36

SE Simulation Continues to Dive Deeper into FEA

Functionality
Without Pre-Load/Contact First Mode 1.472608 Hz
Page 37


Functionality
With Pre-Load/Contact First Mode 7.586033 Hz
Page 38


Functionality
First Mode 415% Higher!!!
Page 39


Structural Behavior
Static Stress, Deflection, Load Distribution Linear
Linear Contact
Dynamic
Frequency Response (Sinusoidal)
Transient Response (General Time-Varying Loads)
Non-Linear
Contact
Thermal
Steady-State
Transient
Page 40

Advanced Dynamics Examples

Sample Model
Tubular Structure
Supports Offset Payload/Mass
Subject to Lateral +/- X Forces
Page 41


Idealized Model beam elements for tubes and lugs, shell mesh at base
Page 42


Always do a modal run first and make sure everything makes sense
Evaluate basic modes/natural frequencies
Page 43


Frequency Response Check Response at the end of the support arm to
frequencies between 0 and 30 Hz.
Request responses
between 0.0 and 30.0,
every 0.2 Hz
Page 44

Advanced Dynamics Example

Frequency Response Limit Output, in this sweep, we are asking for 150
sets of Output, recover responses where they matter most, in this case, out
at the end of the arm.
Page 45


Use Stick and Plate model for preliminary design/sanity check
Update design as necessary
Create detailed Shell or Solid model of final design, run Frequency
Response at actual operating frequencies for final validation
Page 46


Stick and Plate Model 2104
Nodes
All Shell Model 18,115
Nodes
Page 47

Frequency Response Results
Page 48

Overview - Discussion
To get good results, accurately model your structure
Material Properties, linear, non-linear
Linear or nonlinear overall behavior

Boundary Conditions
Loads
Structure Does your mesh accurately reflect the structure

Most Critical Stress condition may not be covered by linear static analysis
Page 49

Contact Information
Mark A. Sherman
sherman.mark@siemens.com
610-458-6502
Page 50

Thank You!
Questions?
#SEU12

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An Introduction to FEA via Solid

Edge and FEMAP

Siemens AG 2012. All Rights Reserved.

Founded by George Rudy, 1985

Mission PC-based dedicated Pre- and

Originally a Pre-Processor Only for

Rapid Growth from 1992 on

Significant strength in Aerospace

Laboratory Module of the ISS (Boeing)

OEM Partnership MSC/Nastran for

Tens of thousands of licenses worldwide

Siemens AG 2012. All Rights Reserved.

Continuous development with the

FEMAP Development Team is all engineers turned programmers

Siemens AG 2012. All Rights Reserved.

Why use Finite Element Analysis

Siemens AG 2012. All Rights Reserved.

Why use Finite Element Analysis

Reduce requirement for physical testing

Maximize these benefits - Important to integrate FEA into the Design

Siemens AG 2012. All Rights Reserved.

Customer Success Stories - Duracast

Siemens AG 2012. All Rights Reserved.

Space Exploration Technologies

"On the analysis front Femap and

Siemens AG 2012. All Rights Reserved.

A Brief History of FEA and FEM

Siemens AG 2012. All Rights Reserved.

Strain- displacement relations

Siemens AG 2012. All Rights Reserved.

Solution for Multiple DOFs

Element stiffness matrix

All element matrices are assembled into a global stiffness matrix

Modeling of Real Structures

Contributions from all other elements

Siemens AG 2012. All Rights Reserved.

Why use Finite Element Analysis

Siemens AG 2012. All Rights Reserved.

Linear Static Analysis

90%+ of all FEA projects

100% Linear if you double the loads,

Material stays in the elastic range

Loads are applied slow and

Siemens AG 2012. All Rights Reserved.

FEA Building Blocks

Numerous Element Types

This makes it possible to accurately model

Results interpretation time

Another consideration for solids is time to

Siemens AG 2012. All Rights Reserved.

Siemens AG 2012. All Rights Reserved.

Siemens AG 2012. All Rights Reserved.

Very versatile offsets and tapers can

Siemens AG 2012. All Rights Reserved.

Plate and Shell Elements

Siemens AG 2012. All Rights Reserved.

Siemens AG 2012. All Rights Reserved.

Linear Static Analysis

What can you expect to learn from a

Siemens AG 2012. All Rights Reserved.

Linear Static Analysis Modeling Guidelines

Siemens AG 2012. All Rights Reserved.

Mesh density required is a function of the desired answers