Basics of FEM Dos and Donts, common mistakes

(Workshop on Advanced NonLinear Finite Element Analysis April 9-10th 2010: COEP Pune)

B Sreehari Kumar
Email: sreehari.kumar@pro-sim.com Sreeharikumar.b@gmail.com

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Overview
Background Basics of Solid Mechanics Finite Element Method - A numerical tool for designers Sources of Error in the FEM Technologies that Compete With the FEM Future Trends in the FEM and Simulation Selected FEM Resources on the Internet
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BACKGROUND
The finite element method is a numerical and computer-intensive technique of solving a variety of practical engineering problems that arise in different fields including, heat transfer, fluid mechanics, and solid and structural mechanics. Computer implementation of the method is modular, and allows general purpose as well as special purpose computer code development with different types of elements and degrees of approximation. There exist a large number of general purpose finite element computer programs (e.g., ABAQUS, ADINA, ANSYS, MSCNASTRAN, NISA, etc) with varying degree of sophistication and analysis capabilities to analyze physical problems with complex domains, physical features (e.g., geometric and material nonlinearities), and subjected to thermal, mechanical and/or hydrodynamic loads. The main task of an engineer or scientist in using a readily available finite-element computer program or developing a finite-element computer program for his or her specific problem lies in the understanding of the basic theory governing the problem, underlying assumptions and limitations of the theory, and the details of the finite element model.
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Engineering mechanics and Industry

Engineering mechanics Stress Analysis Seismic Analysis Vibration Analysis Laminated Composite Analysis Fatigue and Fracture Analysis Optimization Motion and Linkage Analysis Rotor Dynamics Thermal Analysis Printed Circuit Board (PCB) Analysis Computational Fluid Dynamics (CFD) Analysis Electromagnetic Analysis MEMS & NANO Devices Crash Simulations Engineering Industry

Automobile Rail, Road Space Nuclear Defense Heavy Engineering Ship Technology Civil Engg. Structures Bio Medical Engineering

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Stress
Definition of Stress: Stress is the internal resistance of a material to the distorting effects of an external force or load. Stress = = P / A where: = stress ; P = applied force; A = cross-sectional area Three types of stress: Tensile stress is the type of stress in which the two sections of material on either side of a stress plane tend to pull apart or elongate. Compressive stress is the reverse of tensile stress. Adjacent parts of the material tend to press against each other. Shear stress exists when two parts of a material tend to slide across each other upon application of force parallel to that plane Types of Stresses: Structural Stress, Residual Stresses, Pressure Stresses, Flow Stresses, Thermal Stresses, Fatigue Stresses
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Strain

Definition of Strain. Strain is the proportional dimensional change, or the intensity or degree of distortion, in a material under stress. Strain = = /L where: = strain; = total elongation; L = original length Two types of strain: Elastic strain is a transitory dimensional change that exists only while the initiating stress is applied and disappears immediately upon removal of the stress. Plastic strain (plastic deformation) is a dimensional change that does not disappear when the initiating stress is removed. The phenomenon of elastic strain and plastic deformation in a material are called elasticity and plasticity, respectively.
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Hooks Law & Youngs Modulus

Hooks Law: Hooke's Law states that in the elastic range of a material strain is proportional to stress. It is measured by using the following equation: = Pl / AE P = force producing extension of bar l = length of bar A = cross-sectional area of bar = total elongation of bar E = elastic constant of the material, called the Modulus of Elasticity, or Young's Modulus Young's Modulus: Young's Modulus (Elastic Modulus) is the ratio of stress to strain, or the gradient of the stress-strain graph. It is measured using the following equation: E = / Where E = Young's Modulus; = stress; = strain
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Stress vs. Strain

Strain:

Stress: = A

Hookes law:

= E
Where: E = Modulus of Elasticity

= stress = strain

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Generalized Hookes Law Contd..

By superposition of the components of strain in the x, y, and z directions, the strain along each axis can be written as:

1 x = [ x v( y + z )] E 1 y = [ y v( z + x )] E 1 z = [ z v( x + y )] E
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Generalized Hookes Law Contd.. The shearing stresses acting on the unit cube produce shearing strains.

xy = G xy

yz = G yz
xz = G xz
The proportionality constant G is the modulus of elasticity in shear, or the modulus of rigidity. Values of G are usually determined from a torsion test. For isotropic material

E G= 2(1 + v )
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Force

Static Force Dynamic Force Transient, Frequency response, Random, Shock Response Force due to Contact Force due to Creep

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Theories associated with Solid mechanics Theory of elasticity equilibrium equations in X, Y and Z directions are:

Theory of plasticity Theory of beams Theory of plates Theory of shells Contact Mechanics
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Classification of Solid-Mechanics Problems

Analysis of solids Static Dynamics

Elementary
Behavior of Solids

Advanced
Stress Stiffening Large Displacement Geometric Linear Nonlinear Fracture Material Geometric Classification of solids Plasticity Viscoplasticity Instability

Skeletal Systems 1D Elements Trusses Cables Pipes

Plates and Shells 2D Elements Plane Stress Plane Strain Axisymmetric Plate Bending Shells with flat elements Shells with curved elements

Solid Blocks 3D Elements Brick Elements Tetrahedral Elements General Elements

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Assumptions
Linear Analysis: (1) The displacements are very small and that the material is linearly elastic. (2) The geometry, loading, and constitutive behavior remain unchanged during the entire deformation process. F=cu Non-Linear Analysis: (1) Moderately large displacements and rotations but small strains (rotations of line elements are moderately large, but their extensions and changes of angles between two line elements are small). (2) Large displacements, rotations, and strains (the extension of a line element and angle changes between two line elements are large, and displacements and rotations of a line element are also large).
& [M ] {X& } & & + [C ] {X } + G ( X , X ) =

{F (t )}

[M] - Assembled Mass Matrix ;[C] - Overall Damping Matrix; {X} Displacement [K] - Assembled Stiffness Matrix ;{F(t)} - Forcing Function
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Basic equation for a linear static analysis [K] {u} = {Fapp} + {Fth} + {Fpr} + {Fma} + {Fpl} + {Fcr} + {Fsw} + {Fld} [K] = total stiffness matrix {u} = nodal displacement {Fapp} = applied nodal force load vector {Fth} = applied element thermal load vector {Fpr} = applied element pressure load vector {Fma} {Fpl} {Fcr} {Fsw} {Fld} = = = = = applied element body force vector element plastic strain load vector element creep strain load vector element swelling strain load vector element large deflection load vector
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Geometric Nonlinearity GEOMETRIC NONLINEARITY Large displacements, large rotations, finite strains Total and updated Lagrangian formulation Large strain deformation Stress stiffening Post buckling analysis LOADING Conservative loading (fixed direction force, moment, and pressure) Non-conservative loading (deformation dependent follower concentrated force and follower pressure) Body forces (weight and inertia) Thermal loading (specified temperature vs. time curve)
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Material Nonlinearity
MATERIAL NONLINEARITY Material models include von Mises, Tresca, Mohr-Coulomg, and Drucker-Prager yield criterion Elastic perfectly plastic, elastoplastic with isotropic, kinematic or mixed work hardening Uniaxial stress-strain curve description includes elastic perfectly plastic, elastic linear hardening, elastic piece-wise linear hardening, and Ramberg-Osgood curve Hyperelasticity and rubber-like material behavior, material models include generalized Mooney-Rivlin, Blatz-Ko, Alexander, etc. Creep laws such as Norton, McVetty, Soderberg, Dorn, ORNL, etc. are supported. These laws can be expressed as general functions of time, stress, and temperature Anisotropic elastoplastic material model with linear of piece-wise linear hardening for composite shell elements Temperature dependent inelastic properties User-defined material model
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Material Nonlinearity
*PLASTIC Card Set1: Plasticity properties for elastoplastic material models

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Introduction to the Finite Element Method

What is the finite element method? The Finite Element Method (FEM) is a numerical technique to obtain approximate solutions to a wide variety of engineering problems where the variables are related by means of algebraic, differential and integral equations. Mathematical Model: A set of algebraic, differential, and/or integral equations that govern the physical phenomenon of a particular system. The model is based on a set of assumptions and restrictions placed on the phenomenon and the laws of physics that govern it. Numerical Method: An inexact procedure by which the governing equations can be solved for the dependent (unknowns) variables.

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Introduction to the Finite Element Method

Mathematical Models
A mathematical model of the problem being studied must represent the physics consistent with the goals of the study

Desirable Features of a Computational Approach:

Must preserve all features of the mathematical model in the formulation and associated computational model Avoid ad-hoc approaches to `fix numerical deficiencies of the computational model (robustness)

Where is finite element analysis used?

Finite elements has become the defacto industry standard for solving multidisciplinary engineering problems that can be described by equations of calculus. Applications cut across several industries by virtue of the applications solid mechanics (civil, aerospace, automotive, mechanical, biomedical, electronic), fluid mechanics (geotechnical, aerospace, electronic, environmental, hydraulics, biomedical, chemical), heat transfer (automotive, aerospace, electronic, chemical), acoustics (automotive, mechanical, aerospace), electromagnetics (electronic, aerospace) and many, many more.

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Finite Element Method Defined Many problems in engineering and applied science are governed by differential or integral equations. The solutions to these equations would provide an exact, closed-form solution to the particular problem being studied. Analytical, Classical Methods Separation of variables General solution in terms of series functions Conformal Transformation Integral Transform Technique However, complexities in the geometry, properties and in the boundary conditions that are seen in most real-world problems usually means that an exact solution cannot be obtained or obtained in a reasonable amount of time.
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Finite Element Method Defined (cont.) Current product design cycle times imply that engineers must obtain design solutions in a short amount of time. They are content to obtain approximate solutions that can be readily obtained in a reasonable time frame, and with reasonable effort. The FEM is one such approximate solution technique. The FEM is a numerical procedure for obtaining approximate solutions to many of the problems encountered in engineering analysis. Domain methods Boundary methods Mixed methods
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Finite Element Method Defined (cont.)

In the FEM, a complex region defining a continuum is discretized into simple geometric shapes called elements. The properties and the governing relationships are assumed over these elements and expressed mathematically in terms of unknown values at specific points in the elements called nodes. An assembly process is used to link the individual elements to the given system. When the effects of loads and boundary conditions are considered, a set of linear or nonlinear algebraic equations is usually obtained. Solution of these equations gives the approximate behavior of the continuum or system.
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Finite Element Method Defined (cont.) The continuum has an infinite number of degrees-of-freedom (DOF), while the discretized model has a finite number of DOF. This is the origin of the name, finite element method. The number of equations is usually rather large for most realworld applications of the FEM, and requires the computational power of the digital computer. The FEM has little practical value if the digital computer were not available. Advances in and ready availability of computers and software has brought the FEM within reach of engineers working in small industries, and even students.

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Finite Element Method Defined (cont.) Two features of the finite element method are worth noting. The piecewise approximation of the physical field (continuum) on finite elements provides good precision even with simple approximating functions. Simply increasing the number of elements can achieve increasing precision. The locality of the approximation leads to sparse equation systems for a discretized problem. This helps to ease the solution of problems having very large numbers of nodal unknowns. It is not uncommon today to solve systems containing a million primary unknowns.

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Origins of the Finite Element Method

It is difficult to document the exact origin of the FEM, because the basic concepts have evolved over a period of 150 or more years. The term finite element was first coined by Clough in 1960. In the early 1960s, engineers used the method for approximate solution of problems in stress analysis, fluid flow, heat transfer, and other areas. The first book on the FEM by Zienkiewicz and Chung was published in 1967. In the late 1960s and early 1970s, the FEM was applied to a wide variety of engineering problems.

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Origins of the Finite Element Method (cont.)

The 1970s marked advances in mathematical treatments, including the development of new elements, and convergence studies. Most commercial FEM software packages originated in the 1970s (ABAQUS, ADINA, ANSYS, MARK, NISA/DISPLAY, PAFEC) and 1980s (FENRIS, LARSTRAN 80, SESAM 80.) The FEM is one of the most important developments in computational methods to occur in the 20th century. In just a few decades, the method has evolved from one with applications in structural engineering to a widely utilized and richly varied computational approach for many scientific and technological areas.

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Steps in Finite Element Method

Step 1 - Discretization: The problem domain is discretized into a collection of simple shapes, or elements. Step 2 - Develop Element Equations: Developed using the physics of the problem, and typically Galerkins Method or variational principles. Step 3 - Assembly: The element equations for each element in the FEM mesh are assembled into a set of global equations that model the properties of the entire system. Step 4 - Application of Boundary Conditions: Solution cannot be obtained unless boundary conditions are applied. They reflect the known values for certain primary unknowns. Imposing the boundary conditions modifies the global equations. Step 5 - Solve for Primary Unknowns: The modified global equations are solved for the primary unknowns at the nodes. Step 6 - Calculate Derived Variables: Calculated using the nodal values of the primary variables.

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Process Flow in a Typical FEM Analysis

Problem Definition Analysis and design decisions

Start

Stop

Processor Pre-processor
Reads or generates nodes and elements (ex: ANSYS) Reads or generates material property data. Reads or generates boundary conditions (loads and constraints.) Generates element shape functions Calculates master element equations Calculates transformation matrices Maps element equations into global system Assembles element equations Introduces boundary conditions Performs solution procedures

Post-processor
Prints or plots contours of stress components. Prints or plots contours of displacements. Evaluates and prints error bounds.

Step 6

Step 1, Step 4

Steps 2, 3, 5

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Theoretical Basis: Formulating Element Equations Several approaches can be used to transform the physical formulation of a problem to its finite element discrete analogue. If the physical formulation of the problem is described as a differential equation, then the most popular solution method is the Method of Weighted Residuals. If the physical problem can be formulated as the minimization of a functional, then the Variational Formulation is usually used.

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Theoretical Basis: MWR

One family of methods used to numerically solve differential equations are called the methods of weighted residuals (MWR). In the MWR, an approximate solution is substituted into the differential equation. Since the approximate solution does not identically satisfy the equation, a residual, or error term, results. Consider a differential equation Dy(x) + Q = 0 (1) Suppose that y = h(x) is an approximate solution to (1). Substitution then gives Dh(x) + Q = R, where R is a nonzero residual. The MWR then requires that W i(x)R(x) = 0 (2)

where W i(x) are the weighting functions. The number of weighting functions equals the number of unknown coefficients in the approximate solution.
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Theoretical Basis: Galerkins Method

There are several choices for the weighting functions, W i. In the Galerkins method, the weighting functions are the same functions that were used in the approximating equation. The Galerkins method yields the same results as the variational method when applied to differential equations that are self-adjoint. The MWR is therefore an integral solution method. Many readers may find it unusual to see a numerical solution that is based on an integral formulation.

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Advantages of the Finite Element Method

Can readily handle complex geometry: The heart and power of the FEM. Can handle complex analysis types: Vibration Transients Nonlinear Heat transfer Fluids Can handle complex loading: Node-based loading (point loads). Element-based loading (pressure, thermal, inertial forces). Time or frequency dependent loading. Can handle complex restraints: Indeterminate structures can be analyzed.
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Advantages of the Finite Element Method (cont.)

Can handle bodies comprised of nonhomogeneous materials: Every element in the model could be assigned a different set of material properties. Can handle bodies comprised of nonisotropic materials: Orthotropic Anisotropic Special material effects are handled: Temperature dependent properties. Plasticity Creep Swelling Special geometric effects can be modeled: Large displacements. Large rotations. Contact (gap) condition.
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Disadvantages of the Finite Element Method A specific numerical result is obtained for a specific problem. A general closed-form solution, which would permit one to examine system response to changes in various parameters, is not produced. The FEM is applied to an approximation of the mathematical model of a system (the source of so-called inherited errors.) Experience and judgment are needed in order to construct a good finite element model. A powerful computer and reliable FEM software are essential. Input and output data may be large and tedious to prepare and interpret.

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Disadvantages of the Finite Element Method (cont.)

Numerical problems: Computers only carry a finite number of significant digits. Round off and error accumulation. Can help the situation by not attaching stiff (small) elements to flexible (large) elements.

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FINITE ELEMENT LIBRARY

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Information Available from Various Types of FEM Analysis

Static analysis Deflection Stresses Strains Forces Energies Heat transfer analysis Temperature Heat fluxes Thermal gradients Heat flow from convection faces

Dynamic analysis Fluid analysis Frequencies Pressures Deflection (mode shape) Gas temperatures Stresses Convection coefficients Strains Forces Velocities Energies

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Warning: The Computed Answer May Be Wrong

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Sources of Error in the FEM

The three main sources of error in a typical FEM solution are discretization errors, formulation errors and numerical errors. Discretization error results from transforming the physical system (continuum) into a finite element model, and can be related to modeling the boundary shape, the boundary conditions, etc.

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Discretization error due to poor geometry representation.

Discretization error effectively eliminated.

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Sources of Error in the FEM (cont.) Susceptible to user-introduced modeling errors:

Poor choice of element types. Distorted elements. Geometry not adequately modeled.

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Sources of Error in the FEM (cont.)

Formulation error results from the use of elements that don't precisely describe the behavior of the physical problem. Elements which are used to model physical problems for which they are not suited are sometimes referred to as ill-conditioned or mathematically unsuitable elements.
For example a particular finite element might be formulated on the assumption that displacements vary in a linear manner over the domain. Such an element will produce no formulation error when it is used to model a linearly varying physical problem (linear varying displacement field in this example), but would create a significant formulation error if it used to represent a quadratic or cubic varying displacement field.

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Sources of Error in the FEM (cont.)

Numerical error occurs as a result of numerical calculation procedures, and includes truncation errors and round off errors. Numerical error is therefore a problem mainly concerning the FEM vendors and developers. The user can also contribute to the numerical accuracy, for example, by specifying a physical quantity, say Youngs modulus, E, to an inadequate number of decimal places.
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Meshing Guidelines Meshing of rounding (bents) r 3mm Meshed with 1 element or 90deg. r > 3mm Meshed with 2, 3 or 4 elements Holes Modeling The mesh around hole has 2 rosettes. If there is not enough place, mesh with 1 rosette. The physical property of rosettes is same as the sheet around it. Hole dia. d<6mm leave out holes Hole dia 6mm d < 10mm use 6-edges 10mm d use 8 edges

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Meshing Guidelines

Bolt Modeling Inner dia. bore hole diameter Outer dia. of first rosette : Bolt flange dia. Outer dia. of second rosette : triple of bolt dia. Thickness of first rosette : sheet thickness + bolt head height Bolt Shank is modeled by CBAR with bolt nominal dia. The rosettes must be parallel to the part direction.
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Meshing Guidelines
Meshing Crossover If there exist a crossover between smaller and larger parts, a mild crossover is needed. In one elementline the edge-length can be doubled at most. Then follow a line with only quadratic elements. And then the crossover is allowed again. Weld lines: the quality of elements next to a weld line is important. (triangles should not be used) shell thickness Min [d1:d2] Contact: The contact parts meshed with the Collinear nodes The Nodes are connected with the CBAR Elements with only axial stiffness
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Technologies that compete with the FEM

Other numerical solution methods: Finite differences Approximates the derivatives in the differential equation using difference equations. Useful for solving heat transfer and fluid mechanics problems. Works well for two-dimensional regions with boundaries parallel to the coordinate axes. Cumbersome when regions have curved boundaries. Weighted residual methods (not confined to a small subdomain): Collocation Subdomain Least squares* Galerkins method* Variational Methods* (not confined to a small subdomain) * Denotes a method that has been used to formulate finite element solutions.
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Technologies that Compete With the FEM (cont.)

Prototype Testing Reliable. Well-understood. Trusted by regulatory agencies Results are essential for calibration of simulation software. Results are essential to verify modeled results from simulation. Non destructive testing (NDT) is lowering costs of testing in general. Expensive, compared to simulation. Time consuming. Development programs that rely too much on testing are increasingly less competitive in todays market. Faster product development schedules are pressuring the quality of development test efforts. Data integrity is more difficult to maintain, compared to simulation.

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Future Trends in the FEM and Simulation

The FEM in particular, and simulation in general, are becoming integrated with the entire product development process (rather than just another task in the product development process): FEM cannot become the bottleneck. A broader range of people are using the FEM: Not just hard-core analysts. Increased data sharing between analysis data sources (CAD, testing, FEM software, ERM software.) FEM software is becoming easier to use: Improved GUIs, automeshers. Increased use of sophisticated shellscripts and wizards., API for customized development.
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Future Trends in the FEM and Simulation (cont.)

Enhanced multiphysics capabilities are coming: Coupling between numerous physical phenomena. Ex: Fluid-structural interaction is the most common example. Ex: Semiconductor circuits, EMI and thermal buildup vary with current densities. Ex: Smart Structures; Nano technology (MEMS-Micro-electromechanical-systems), MEOMS(micro-opto-electro-mechanical systems). Utilizes micro machanics and micro machanics Improved life predictors, improved service estimations. Increasing use of non-deterministic analysis and design methods: Statistical modeling of material properties, tolerances, and anticipated loads. Sensitivity analyses. Faster and more powerful computer hardware. Massively parallel processing, 64 bit computing, Multi core systems. Decreasing reliance on testing. FEM and simulation software available via Internet subscription.
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Selected FEM Resources on the Internet

http://www.engineeringzones.com - A website created to educate people in the latest engineering technologies, manufacturing techniques and software tools. Exellent FEM links, including links to all commercial providers of FEM software. http://www.comco.com/feaworld/feaworld.html - Extensive FEM links, categorized by analysis type (mechanical, fluids, electromagnetic, etc.) http://femur.wpi.edu - Extensive collection of elementary and advanced material relating to the FEM. http://www.engr.usask.ca/%7Emacphed/finite/fe_resources/fe_resources.html - Lists many public domain and shareware programs. http://sog1.me.qub.ac.uk/dermot/ferg/ferg.html#Finite - Home page of the the Finite Element Research Group at The Queen's University of Belfast. Excellent set of FEM links. http://www.tenlinks.com/cae/ - Hundreds of links to useful and interesting CAE cited, including FEM, CAE, free software, and career information. http://www.geocities.com/SiliconValley/5978/fea.html - Extensive FEM links. http://www.nafems.org/ - National Agency for Finite Element Methods and Standards (NAFEMS). engineering your designs www.pro-sim.com

Thank you

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