Finite Element Analysis

Randall Bock, Professor of Continuing Education The Pennsylvania State University

Who am I ?

rgb@psu.edu

Research Engineer Professor of Continuing Education Happy Valley SWUG, Leader CSWP, CSSP

Week 1

EDSGN 496A: SolidWorks

SKETCH: The Design Environment Introduction, Objectives, and Goals User Interface Associative Design Design Intent & Constraints CommandManager: Sketch & Features Extruded Base Basic Strategy

Fundamentals

Image courtesy of Innovation Engineering Inc.

www.hvswug.org

The Plan

SolidWorks Simulation
Traditional Design What is the Finite Element Method SolidWorks Simulation FEA Fundamentals Linear Study Mesh: Controlling, Converging & Analyzing Symmetry, Singularities, Simplification Nonlinear Study Examples, Tips, and Tricks Throughout

A Traditional Design Cycle

Build a 3D model. Manufacture prototype. Test the prototype. Analyze results

modify the model build a new prototype test it again repeat

SolidWorks

$ Prototype

Test

Satisfied? Yes Mass Production

No

FEA Integrated Design Cycle

SolidWorks FEA

Satisfied? Yes

No

$ Prototype
No

Test

Mass Production

What is the FEM ?

SolidWorks Simulation

Tools > SimulationXpress

SimulationXpress

Limitations
1. PARTs (one solid body) 2. Static analysis only (stress) 3. Optimize one variable 4. Isotropic materials 5. Uniform loads 6. Fixed restraints

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SolidWorks Simulation 2010

Simulation Premium
Simulation Professional
Static* Frequency Buckling Thermal Drop Test Linear Dynamics Nonlinear

Flow Simulation

Motion*

Fatigue

Optimization

Pressure Vessel

Event-based EventMotion Composites

Sustainability

*Included with SolidWorks Premium

SolidWorks Simulation

Tools > Add-Ins

Advantages
Parts & Assemblies Non-linear, thermal, buckling, frequency, drop test, optimization, fatigue Isotropic & orthotropic materials Uniform & non-uniform loads Multiple restraints More

FEA Fundamentals

FEA Fundamentals

Define and discretize the domain Specify approximating function and B.C. Create and converge system of equations Resolve for quantities of interest

FEA Fundamentals

Define the domain

FEA Fundamentals

Discretize the domain

MESH

FEA Fundamentals

Discretize using tetrahedrons: 1st order (linear)

1 element 4 nodes
First Order Structural Tetrahedron Element: 4 nodes 12 dof 12 x 12 matrix

FEA Fundamentals

Discretize using tetrahedrons: 2nd order (quadratic)

1 element 10 nodes
Second Order Structural Tetrahedron Element: 10 nodes 30 dof 30 x 30 matrix

FEA Fundamentals

Discretize using tetrahedrons: 2nd order

1 element 10 nodes
Second Order Structural Tetrahedron Element: 10 nodes 30 dof 30 x 30 matrix

Curved

FEA Fundamentals

Neighboring elements share nodes

4 element 7 nodes DOF ?

FEA Fundamentals

Cube
12 element 9 nodes DOF ?

FEA Fundamentals

Specify approximating function

And also an

FEA Fundamentals

Specify approximating function

FEA Fundamentals

Specify approximating function (2D Triangle, linear) u ( e ) ( x, y ) = o + 1 x + 2 y

EACH ELEMENT

FEA Fundamentals

Specify approximating function (new node values) u ( e ) ( x, y ) = o + 1 x + 2 y

FEA Fundamentals

Specify approximating function (unknown coefficients) u ( e ) ( x, y ) = o + 1 x + 2 y

FEA Fundamentals

Specify approximating function (current node values) u ( e ) ( x, y ) = o + 1 x + 2 y

FEA Fundamentals

Specify approximating function (2D Triangle, quadratic) u ( e ) ( x, y ) = o + 1 x + 2 y + 3 x 2 + 4 xy + 5 y 2

Sidebar

FEA Fundamentals

Sidebar

FEA Fundamentals

Specify approximating function u ( e ) ( x, y ) = o + 1 x + 2 y

FEA Fundamentals

Specify approximating function u ( e ) ( x, y ) = o + 1 x + 2 y

Equilibrium equations

(Hooks Law 2D)

E u v u v + +G + = 0 + y y x 1 2 x x y E u v u v +G + + y x 1 2 x + y = 0 x

FEA Fundamentals

Specify approximating function u ( e ) ( x, y ) = o + 1 x + 2 y

Equilibrium equations

(Hooks Law 2D)

E u v u v + +G + = 0 + y y x 1 2 x x y E u v u v +G + + y x 1 2 x + y = 0 x

FEA Fundamentals

Specify approximating function u ( e ) ( x, y ) = o + 1 x + 2 y

Equilibrium equations

(Hooks Law 2D)

E u v u v + +G + = 0 + y y x 1 2 x x y E u v u v +G + + y x 1 2 x + y = 0 x

Moduli conversion

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Approximate Solution
Hooks Law
+ E u v u v + +G + = 0 2 x y y y x 1 x E u v u v + + y x 1 2 x + y = 0 x

u ( e ) ( x, y ) = o + 1 x + 2 y

+G

FEA Fundamentals

Specify approximating function u ( e ) ( x, y ) = o + 1 x + 2 y

Equilibrium equations

(Hooks Law 2D)

E u v u v + +G + = 0 + y y x 1 2 x x y E u v u v +G + + y x 1 2 x + y = 0 x

FEA Fundamentals

Specify approximating function u ( e ) ( x, y ) = o + 1 x + 2 y

Equilibrium equations

(Hooks Law 2D)

E u v u v + +G + = 0 + y y x 1 2 x x y E u v u v +G + + y x 1 2 x + y = 0 x

v Slope Field: =vx x v

v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x v x

Solutions:

v =vx x v

Solutions:

v =vx x v

FEA Fundamentals

Specify the boundary conditions

Load

Restraint

FEA Fundamentals (basic strategy)

Create and converge system of equations

1) Plug initial mesh geometry into

u ( e ) ( x, y ) = o + 1 x + 2 y

2) Plug new node values from 1) into

+ E u v u v + +G + = 0 2 x y y y x 1 x E u v u v + + y x 1 2 x + y = 0 x

+G

3) Subtract 1) from 2)

4) Difference 3) drives next iteration

FEA Fundamentals

Resolve for other quantities of interest, e.g.

Strain () Stress () von Mises Stress: eq = 0.5[( 1 2 )2 + ( 2 3 )2 + ( 3 1 )2 ]

Linear

Linear elastic stress analysis

Small displacements with constant b.c. Material properties constant (ductile) Load applied slowly
Ultimate or Tensile Yield

Defining a Study
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

(fea fundamentals)

Define the type of analysis. (specify approx. function) Create a study. Define material for each component. Define Connections. (b.c.: component-component) Define Fixtures. (b.c.: reduce model DOF) Define External Loads. (b.c.: force, pressure, torque) Define the Mesh. (discretize the domain) Run the analysis. (solve linear system) View Results. Interpret results.

Analytical vs. FEA (node)

FEA Solution

max = Kn n
Stress concentration factor, (flat plate, circular hole, D/W>0.65):

D K n = 2 + 1 W
Normal stress, at hole cross section:

n =
Plate geometry:

P (W D) T

D = hole diameter = 70 mm W = plate width = 100 mm T = plate thickness = 10 mm

Load:

P = tensile load = 50,000 N

max = 338 MPa

National Agency for Finite Element Methods and Standards

NAFEMS Benchmarks... Help > SolidWorks Simulation > Validation > NAFEMS Benchmarks.

Flat Plate: vonMises (MPa) vs DOF

Mesh

vonMises* 327 341 349 348

DOF 7,944 46,728 281,142 52,368

Coarse Default Fine Default w/ mesh ctrl.

* eq =

0.5 ( 1 2 ) + ( 2 3 ) + ( 3 1 )
2 2

Mesh

t lmos a Its ^all about

the Mesh

Sidebar

Delaunay & Voronoi

Sidebar

vonMises (MPa): Default Nodes

vonMises (MPa): Default Elements

vonMises (MPa): Fine Nodes

vonMises (MPa): Fine Elements

Mesh > Details : Aspect Ratio

perfect tetrahedral element is 1.0

Adaptive Mesh: error reduction

p-adaptive: more efficient elements

up to 5th order approximation function

u( x, y ) = o + 1 x + 2 y + 3 x 2 + 4 y 2 + 5 x 3 + 6 y 3

( x, y ) = o + 1 x + 2 y + 3 x 2 + 4 y 2 + 5 x 3 + 6 y 3

h-adaptive: smaller elements where needed

Symmetry ?

SYMMETRY IS A BIG DEAL

Kindergarten Entrance Exam

Sidebar

Consider Symmetry

Simplification: Symmetry

Simplification: Symmetry & 3D

Simplification: Symmetry & 2D

vonMises vs. Degree of Freedom

Fine Mesh Control Default Coarse Shell

Flat Plate: vonMises (MPa) vs DOF

Mesh

vonMises 326 340 349 352 347

DOF 7,902 46,581 280,218 52,197 1,531

Coarse Default Fine Default w/ mesh ctrl. Symmetry Shell

Singularity

Reentrant Corner
Force

! uc h O
Force

Consider Singularity: L-Bracket (MPa)

Study

Sharp Corner 76 92 194 -

Radius Corner 101 101 101 115

Mesh Control 1 Mesh Control 2 Mesh Control 3 Adaptive Mesh

Simplify & Split

McMaster-Carr

Work Load Limit Given

Simplify Geometry

Suppress nut & thread

Insert > Curve > Split Line

Split Line

Assembly Analysis

Assembly Analysis

Beam Elements

Beam Analysis

Shear Plot

LARGE DISPLACEMENT

Time to consider nonlinear solutions

Nonlinear

Nonlinear stress analysis

Why?
Material Properties: f (, ) elastic, viscoelastic, plastic Boundary Conditions Geometry
Yield

Nonlinear stress analysis

Why?
Material Properties Geometric: large spatial u, small local u

Small Displacement

Large Displacement

Nonlinear stress analysis

Why?
Material Properties Geometric: large spatial u, small local u

Small Displacement

Large Displacement

Nonlinear stress analysis

Why?
Material Properties Geometric Boundary Conditions: contact problems

Contact during loading changes stiffness

Nonlinear stress analysis

Why?
Material Properties Geometric Boundary Conditions: contact problems

Contact during loading changes stiffness Large strain

Defining a Nonlinear Study

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Define the type of analysis. Create a study. Define materials Define Connections. Define Fixtures. Define External Loads. Define the Mesh. Run the analysis. View Results. Interpret results.

Defining a Study
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Define the type of analysis. Create a study. Define materials Material > Prop. > Model Type Define Connections. Define Fixtures. Define External Loads. LOAD STEP: force or disp. Define the Mesh. Run the analysis. View Results. Interpret results.

Apply Material

Model Type

Simulation > Research

Define Load Steps (force or disp.)

Resources

Joe Galliera, TTM Simulation, SolidWorks

SolidWorks Tutorials

SolidWorks Web Help

Make Math Fun w/ Direction Field Plotter

http://www.math.psu.edu/cao/DFD/Dir.html

Formula Plotter with Integral Curves

Voronoi / Delaunay Applet

http://www.cs.cornell.edu/home/chew/chew.html

Questions