Finite Element Analysis for Design Engineers

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Finite Element Analysis for Design Engineers

Paul M. Kurowski

Warrendale, Pa.

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Library of Congress Cataloging-in-Publication Data Kurowski, Paul M. Finite element analysis for design engineers / Paul M. Kurowski. p. cm. ISBN 0-7680-1140-X 1. Finite element method. 2. Engineering designData processing. I. Title. TA347.F5K83 2004

620'.0042dc22 2004054717
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Copyright 2004

SAE International

ISBN 0-7680-1140-X SAE Order No. R-349 Printed in the United States of America.
Disclaimer: Every effort has been made to provide an accurate text. The author and the manufacturers shall not be held liable for any parts developed with this book or be held responsible for any inaccuracies or errors that may appear in the book.

Acknowledgments
I would like to thank Professor Barna Szabo and his team at Engineering Software Research & Development, Inc. (ESRD) and Vlad Zila at Genexis Design Inc. for their help and support. I also thank my aunt, Wanda Siwek, who inspired me to write this book, and my wife Elzbieta, for her encouragement that made this book possible. Paul M. Kurowski

Table of Contents
Preface Chapter 1 Introduction 1.1 What Is Finite Element Analysis? 1.2 What Is "FEA for Design Engineers?" 1.3 Note on Hands-On Exercises and Illustrations in This Book Chapter 2 From CAD Model to Finite Element Analysis Results 2.1 Formulation of the Mathematical Model 2.2 Selecting the Numerical Method to Solve the Mathematical Model 2.2.1 Numerical Methods in Engineering Analysis 2.2.2 Reasons for the Dominance of the Finite Element Method 2.3 The Finite Element Model 2.3.1 Meshing 2.3.2 Formulation of Finite Element Equations 2.3.3 Errors in FEA Results Chapter 3 Major Concepts of the Finite Element Model 3.1 Formulation of a Finite Element 3.1.1 Shape Functions, Degrees of Freedom, and Element Order 3.1.2 Requirements to Be Satisfied by Shape Functions 3.1.3 Artificial Constraints 3.1.4 The Choices of Discretization 3.2 Types of Finite Elements 3.2.1 Element Dimensionality 3.2.2 Analysis Dimensionality 3.2.3 Element Shape 3.2.4 Element Order and Element Type 3.2.5 Element Modeling Capabilities Chapter 4 Controlling Discretization Errors 4.1 Convergence Process 4.1.1 h-Convergence Process 4.1.2 Convergence Error 4.1.3 Solution Error 4.1.4 p-Convergence Process 4.1.5 Variations in Convergence Processes xi 1 1 2 3 5 5 7 7 8 9 9 10 11 13 13 13 15 15 17 18 19 20 21 21 22 25 25 25 29 29 30 32

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Finite Element Analysis for Design Engineers

4.2 Problems with Convergence 4.2.1 Stress Singularity 4.2.2 Displacement Singularity 4.3 Hands-On Exercises 4.3.1 Tensile Strip with a Circular Hole 4.3.2 L-Shaped Bracket 4.3.3 Spot-Welded Cantilever Chapter 5 Finite Element Mesh 5.1 Meshing Techniques 5.1.1 Manual Meshing 5.1.2 Semi-Automatic Meshing 5.1.3 Automatic Meshing 5.2 Mesh Compatibility 5.2.1 Compatible Elements 5.2.2 Incompatible Elements 5.2.3 Forced Compatibility 5.3 Common Meshing Problems 5.3.1 Element Distortion 5.3.2 Not Enough Elements to Represent Model Stiffness 5.3.3 Incorrect Mapping to Geometry 5.3.4 Incorrect Conversion to Shell Model 5.4 Hands-On Exercises 5.4.1 Hollow Cantilever Bracket 5.4.2 Beam in Bending Chapter 6 Modeling Process 6.1 Modeling Steps 6.1.1 Definition of the Objective of Analysis 6.1.2 Selection of the Units of Measurement 6.1.3 Geometry Creation 6.1.4 Defining Material Properties 6.1.5 Defining Boundary Conditions 6.2 Some Useful Modeling Techniques 6.2.1 Taking Advantage of Symmetry and Anti-Symmetry 6.2.2 Axial Symmetry 6.2.3 Realignment of Degrees of Freedom 6.3 Hands-On Exercises 6.3.1 Cantilever Bracket with Symmetry Boundary Conditions 6.3.2 Cantilever Bracket with Anti-Symmetry Boundary Conditions 6.3.3 Shaft in Torsion 6.3.4 Plate in Bending

34 35 38 42 42 43 45 47 47 47 48 48 50 50 51 52 52 54 55 56 57 58 58 59 61 61 62 62 63 64 64 65 65 68 69 71 71 71 72 73

Table of Contents

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6.3.5 Ring in Bending 6.3.6 Pin-Supported Link Chapter 7 Types of Finite Element Analysis 7.1 Thermal Analysis 7.1.1 Heat Flow Induced by Prescribed Temperatures 7.1.2 Heat Flow Induced by Heat Load and Convection 7.1.3 Modeling Considerations in Thermal Analysis 7.2 Nonlinear Analysis 7.2.1 Nonlinear Material 7.2.2 Nonlinear Geometry 7.2.3 Contact Stress Analysis 7.3 Modal Analysis 7.3.1 Differences Between Modal and Static Analyses 7.3.2 Interpretation of Displacement and Stress Results in Modal Analysis 7.3.3 Modal Analysis with Rigid Body Modes 7.3.4 Importance of Supports in Modal Analysis 7.3.5 Applications of Modal Analysis 7.3.6 Pre-Stress Modal Analysis 7.3.7 Symmetry and Anti-Symmetry Boundary Conditions in Modal Analysis 7.3.8 Convergence of Modal Frequencies Results 7.3.9 Meshing Considerations for Modal Analysis 7.4 Buckling Analysis 7.4.1 Buckling Load Factor 7.4.2 Interpretation of Results of Buckling Analysis 7.5 Dynamic Analysis 7.5.1 Modal Superposition Method 7.5.2 Time Response Analysis 7.5.3 Frequency Response Analysis 7.6 Hands-On Exercises 7.6.1 Crossing Pipes 7.6.2 Radiator 7.6.3 Cantilever Bracket, Elasto-Plastic Material 7.6.4 Slender Cantilever Beam in Bending 7.6.5 Round Membrane Under Pressure 7.6.6 Tuning Fork 7.6.7 U-Shaped Support Bracket 7.6.8 Unsupported and Hinge-Supported Beam 7.6.9 Hollow Cantilever Bracket, Modes Separation 7.6.10 Beam in Compression

74 75 77 77 77 78 79 80 81 84 89 92 93 94 94 94 95 97 97 99 99 99 100 100 101 101 102 104 106 106 107 108 109 110 111 112 113 114 115

Finite Element Analysis for Design Engineers

Chapter 8 Design Optimization 8.1 Topological Optimization 8.2 Structural Optimization 8.2.1 Factors Defining an Optimization Process 8.2.2 Sensitivity Studies Chapter 9 Using Finite Element Analysis in the Design Process 9.1 Differences Between CAD and FEA Geometries 9.1.1 Defeaturing 9.1.2 Idealization 9.1.3 Cleanup 9.1.4 Common Meshing Problems 9.1.5 Mesh Inadequacy 9.2 Integration of CAD and FEA Software 9.2.1 Standalone FEA Software 9.2.2 Integrated FEA Software 9.3 FEA Implementation 9.3.1 Positioning of CAD and FEA Activities 9.3.2 Personnel Training 9.3.3 Software Selection Criteria 9.3.4 Building Confidence in the FEA 9.3.5 Expected Return on Investment 9.4 FEA Projects 9.4.1 Major Steps in an FEA Project 9.4.2 FEA Report 9.4.3 Importance of Documentation and Backups 9.4.4 Contracting Out FEA Services 9.4.5 Common Errors in FEA Management Chapter 10 Some Misconceptions and Frequently Asked Questions 10.1 FEA Quiz 10.2 Frequently Asked Questions About FEA Chapter 11 Finite Element Analysis Resources Chapter 12 Glossary of Terms Index About the Author

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151 151 155 169 171 177 187

Preface
During the 50 years of its development, finite element analysis (FEA) evolved from an exotic analysis method accessible only to specialized analysts into a mainstream engineering tool. Phenomenal progress in computer hardware and operating systems, combined with similar progress in computer-aided design (CAD), made FEA the tool of choice for design engineers, who now use it during the product design process. Many books have been written about FEA. At one end of the spectrum, we find books going deep into theory; at the other end of the spectrum, software manuals teach how to use FEA software. There is very little FEA literature that takes a "middle ground" approach and specifically addresses the needs of design engineers who use FEA as an everyday design tool. This book attempts to fill that void by focusing on an understanding of FEA fundamentals, which are explained by simple and intuitive examples that can be grasped by any engineer. This book also takes a practical approach, characteristic to the attitudes of design engineers, and offers readers an opportunity to try all discussed topics by solving downloadable exercises using either their own FEA software or the commercial FEA software StressCheck, which is licensed for free to readers.