Finite Element Method

An Introduction
K.H.J. Mangala

What is FEM?
The finite element method is a numerical method for solving problems of engineering and mathematical physics. Useful for problems with complicated geometries, loadings, and material properties where analytical solutions can not be obtained.
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Discretizations
Model body by dividing it into an equivalent system of smaller bodies or units (finite elements) interconnected at points common to two or more elements (nodes or nodal points) and/or boundary lines and/or surfaces.

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History
Grew out of aerospace industry. Post-WW II jets, missiles, space flight Need for light weight structures Required accurate stress analysis Paralleled growth of computers
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Introduction
Finite element analysis is a powerful tool that allows engineers to quickly analyze and refine a design.

Introduction
FEA can be applied to problems involving: structural design

Introduction
Vibrations

Introduction
Heat Transfer

Introduction
Sheet metal parts

Introduction
Product Design

Introduction
Product Design

Introduction
In a structural simulation, FEM helps tremendously in producing stiffness and strength visualizations and also in minimizing weight, materials, and costs FEM allows detailed visualization of where structures bend or twist, and indicates the distribution of stresses and displacements.

Introduction
FEA is extensively used in Aerospace industry, automobile industry, computer hardware development,

Introduction
Obtain a set of algebraic equations to solve for unknown nodal quantity (displacement). Secondary quantities (stresses and strains) are expressed in terms of nodal values of primary quantity

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Advantages
Irregular Boundaries General Loads Different Materials Boundary Conditions Variable Element Size Easy Modification Dynamics Nonlinear Problems (Geometric or Material)

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Steps in the Process

Discretize and Select Element Type Select a Displacement Function Define Strain/Displacement and Stress/Strain Relationships Derive Element Stiffness Matrix & Eqs. Assemble Equations and Introduce B.C.s Solve for the Unknown Degrees of Freedom Solve for Element Stresses and Strains Interpret the Results
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Computer Programs
Small Special Purpose Programs

Truss Frame Plane Stress Heat Transfer

Large General Purpose Program (Commercial)

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Programs
ALGOR ANSYS COSMOS/M STARDYNE IMAGES-3D MSC/NASTRAN SAP90 ADINA NISA
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General Purpose Programs

Easy input - preprocessor. Solves many types of problems Modular design - fluids, dynamics, heat, etc. Can run on PCs now. Relatively low cost.

Advantages

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General Purpose Programs

Disadvantages

High development costs. Less efficient than smaller programs, Often proprietary. User access to code limited.

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FEA Concept contd.

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FEA Concept contd.

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FEA Concept contd.

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Displacement-Based contd.

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Two-Spring Model contd.

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Two-Spring Model contd.

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Two-Spring Model contd.

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Two-Spring Model contd.

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Two-Spring Model contd.

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Two-Spring Model contd.

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Finite Element Solution Procedure contd.

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Nodes & Elements

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A Typical FE Mesh

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Boundary Conditions

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Finite Element Analysis (FEA)

Historical Note The finite element method of structural analysis was created by academic and industrial researchers during the 1950s and 1960s. The underlying theory is over 100 years old, and was the basis for pen-and-paper calculations in the evaluation of suspension bridges and steam boilers.

FEA is a tool of design analysis Design Analysis: process of investigating certain properties of parts, assemblies or structures

Finite Element Analysis (FEA) - 1

Design analysis can be conducted on:

Real objects Models that represents certain aspects of a real object

If models are used instead of real objects, the analysis can be conducted earlier in the design process before the final product or prototypes are built Models can be physical models or mathematical models Simple mathematical models can be solved analytically, but more complex models require the use of numerical methods

Design Analysis
Design Analysis Real Objects Models

Mathematical Models

Physical Models

Numerical

Analytical Finite Element Method Finite Difference Method Boundary Element Method

Finite Element Analysis (FEA) - 2

Finite Element Analysis (FEA) is one of those numerical methods used to solve complex mathematical models FEA users require familiarity with the mechanics of materials, engineering design, and other topics as required in any Mechanical Engineering curriculum FEA is based on CAD models The ultimate objective of using FEA as a design tool is to change the design process from iterative cycles of design prototype test into a streamlined process where prototypes are used only for final design verification

Design Process: Traditional vs FEA-driven

Traditional Product Design Process FEA-Driven Product Design Process

Design

CAD

FEA

Prototyping

Prototyping

Testing

Testing

Production

Production

With the use of FEA, design iterations are moved from the physical space of prototyping and testing into virtual space of computer-based-simulations

Why is FEA needed?

To reduce the amount of prototype testing

Computer simulation allows multiple what-if scenarios to be tested quickly and effectively.

To simulate designs that are not suitable for prototype testing

Eg: Surgical implants, such as an artificial knee Cost savings Time savings reduce time to market! Create more reliable, better-quality designs

The bottom line:

FEA Modelling Process: Structural Analysis

CAD Model FEA Model Analysis of results

Pre-processing

Solving Post-processing

Pre-processing

Geometry creation CAD model Defining material properties Defining boundary conditions (Loads and Restraints) Meshing

Example with COSMOSXpress

Pre-processing: Geometry Creation CAD Model

Can use any CAD software tool

2D or 3D model Import CAD model to FEA environment using data exchange standards such as IGES (Initial Graphics Exchange Specification) or STEP Reliability of geometry exchange? Integration of CAD and FEA software Selection from existing materials from the library Defining and assigning new material properties

Assigning material

The Finite Element Model

Often, CAD geometry will not satisfy the requirements of FEA geometry

CAD geometry contain all information necessary for part or assembly manufacturing CAD geometry can serve as a starting point in the process of FE model preparation

FEA geometry must be: Meshable Allow for creation of a mesh that is solvable within a reasonable time Converting CAD geometry into FEA-specific geometry Defeaturing Idealization

The Finite Element Model: Meshing 1

Meshing (discretization): A process of splitting the solution domain into simply shaped subdomains called Finite Elements. A continuous body has an infinite number of points or, in other words, an infinite number of degrees of freedom. Discretization replaces it with a system that has a finite number of degrees of freedom possible to solve with numerical methods

The Finite Element Model: Meshing 2 Types of finite elements

The Finite Element Model: Meshing 3

3D tetrahedral solid elements

Nodes

DOF
Translation Rotation

Linear solid element

Parabolic solid element

In general, for the same mesh density (number of elements), parabolic elements yield better results than linear elements because: 1) they represent curved boundaries more accurately, and 2) they produce better mathematical approximations. However, parabolic elements require greater computational resources than linear elements

2D shell elements

The Finite Element Model: Meshing 4

The displacement field inside each element and along its edges is described by certain polynomial functions commonly called shape functions The order of the shape function employed by the element defines the order of the element (first-order element, secondorder element)

Finite element analysis programs look at the model as a network of discrete interconnected elements Elements deform under a load and assume new shape Elements interact with each other through common nodes

The Finite Element Model: Meshing 5

Meshing Techniques

Manual meshing Automatic meshing

Only practical meshing choice for complex models Meshing is done in the background and not visible to the user The user can control the element size