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Introduction to

Finite Element Analysis


by

Prof. N Siva Prasad

Department of Mechanical Engineering
Indian Institute of Technology Madras
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Prof .N. Siva Prasad, Indian Institute of Technology Madras
Why Finite Element Modeling (FEM)?
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Prof .N. Siva Prasad, Indian Institute of Technology Madras
Error
Why FEM? Contd
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Error
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Why FEM? Contd
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Prof .N. Siva Prasad, Indian Institute of Technology Madras
Why FEM? Contd
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Prof .N. Siva Prasad, Indian Institute of Technology Madras
Example
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Prof .N. Siva Prasad, Indian Institute of Technology Madras
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STRESSES AND EQULIBRIUM
Fig. 1 Three-dimensional body
A three-dimensional body occupying a volume V and having a surface S is
shown in Fig.1.
The deformation of a point is given by the three components of its
displacement:
T
= [ ] u,v,w u
(1)
T
( =[x, y, z] ) x
Prof .N. Siva Prasad, Indian Institute of Technology Madras
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The distributed force per unit volume, for example, the weight per unit
volume, is the vector f given by
T
[ ]
x y
f , f , f = f
z
(2)
The body force acting on the elemental volume dV is shown in Fig.1
The surface traction T may be given by
T
]
x y z
T ,T ,T T=[
(3)
A load P acting at a point i is represented by its three components:
T
i i
[ ]
x y z
P ,P ,P = P
(4)
Prof .N. Siva Prasad, Indian Institute of Technology Madras
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The stresses acting on the elemental volume dV are shows Fig. 2.
Fig. 2 Equilibrium of elemental volume
Prof .N. Siva Prasad, Indian Institute of Technology Madras
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The six independent components are
T
x y yz xz xy
[ , , , , , ]
z
= o o o t t t o
(5)
x y z
, , o o o
yz xz xy
, , , t t t
where are normal stresses and
are shear stresses. The equilibrium equations
0
0
0
xy
x xz
x
xy y yz
y
yz
xz z
z
f
x y z
f
x y z
f
x y z
ct
co ct
+ + + =
c c c
ct co ct
+ + + =
c c c
ct
ct co
+ + + =
c c c
(6a)


(6b)


(6c)
Prof .N. Siva Prasad, Indian Institute of Technology Madras
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STRAIN DISPLACEMENT RELATIONS
T
[ , , , , , ]
x y z yz xz xy
= e e e e
(7)
, ,
x y
e e
z
e
, ,
yz xz

xy

where and are normal strains and and


are the engineering shear strains.
Prof .N. Siva Prasad, Indian Institute of Technology Madras
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Fig. 3 Deformed elemental surface
Prof .N. Siva Prasad, Indian Institute of Technology Madras
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The shear strain-displacement can be written as
xy
u v
y x
c c
= +
c c
(8)
Considering the other faces y-z, and z-x,
T
, , , , ,
u v w v w u w u v
x y z z y z x y x
( c c c c c c c c c
e= + + +
(
c c c c c c c c c

(9)
Prof .N. Siva Prasad, Indian Institute of Technology Madras
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y
x z
x
y
x z
y
y
x z
z
v v
E E E
v v
E E E
v v
E E E
o
o o
o
o o
o
o o
e =
e = +
e = +
yz
yz
xz
xz
xy
xy
G
G
G
t

=
=
=
(10)
Stress-strain relations

For linear elastic materials, the stress-strain relations come from the
generalized Hookes law. For isotropic materials, the two material
properties are Youngs modulus (or modulus of elasticity) E and
Poissons ratio . Considering an elemental cube inside the body,
Hookes law gives
v
Prof .N. Siva Prasad, Indian Institute of Technology Madras
The shear modulus (or modulus of rigidity), G is given by
2(1 )
E
G
v
=
+
(11)
From Hookes law relationships (Eqn. 10), adding and LHS
(1 2 )
( )
x y z x y z
v
E
o o o

e +e +e = + +
(12)
Substituting for and so on into Eq. 10, we get the inverse relations
D o = e
(13)
( ) x z o o +
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Prof .N. Siva Prasad, Indian Institute of Technology Madras
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D is the symmetric (6 X 6) material matrix given by
1 0 0 0
1 0 0 0
1 0 0 0
0 0 0 0.5 0 0 (1 )(1 2 )
0 0 0 0 0.5 0
0 0 0 0 0 0.5
v v v
v v v
v v v
E
v v v
v
v

(
(

(
(

=
(
+
(
(


D
(14)
Prof .N. Siva Prasad, Indian Institute of Technology Madras
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Fig. 4 (a) Plane stress

Plane Stress. A thin planar body subjected to in-plane loading on
its edge surface is said to be in plane stress. A ring press fitted on a
shaft, Fig. 4, is an example. Here stresses
are set as zero. The Hookes law relations (Eq. 10) then give us
, , and
z xz yz
o t t
2(1 )
( )
x
y
xy
z
y
x
v
E E
y
x
v
E E
v
xy
E
v
x y
E
o
o
o
o
t
o o
e =
e = +
+
=
e = +
Prof .N. Siva Prasad, Indian Institute of Technology Madras
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(16)

Fig. 4(b) plane strain
( )( )
1 0
1 0
1+ 1 2
0 0 0.5
v v
x x
E
v v
y y
v v
v
xy xy

(

(


(
` `
(

(

(


) )
o e

o = e

t
(17)
D here is a (3x3) matrix.
Plane Strain.
If a long body of uniform cross section is subjected to transverse
loading along its length, are taken as zero. Stress
may not be zero in this case. The stress strain relations can be
obtained

, , and
z xz yz
c
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TEMPERATURE EFFECTS

The temperature strain is represented as an initial strain:

0
T
(

e = oAT, oAT, oAT, 0, 0, 0

(18)
Prof .N. Siva Prasad, Indian Institute of Technology Madras
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Strain Energy stored in the spring
U = (force in the spring) (displacement )
= (Su) u
= s u
2

Potential energy of the external load p
Wp = (load) (displacement from zero potential state)
= - p u
Total potential energy [ = total strain energy + Work potential
[ = U+ Wp
= s u
2
p u
for minimum of [ , c[/cu = 0

S u p = 0
Su = p

Potential energy and equilibrium
Prof .N. Siva Prasad, Indian Institute of Technology Madras
P
u
P
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Potential Energy, [
The total potential energy of an elastic body, is defined as the
sum of total strain energy (U) and the work potential:


[
[
= Strain energy + Work potential
(U) (WP) (22)

For linear elastic materials, the strain energy per unit volume in the body
is . For an elastic body, the total strain energy is given by

1
2
T
o e

V
1
T
2
U dV =
}
o e

(23)
The work potential WP is given by
Prof .N. Siva Prasad, Indian Institute of Technology Madras
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V S
T T T
WP
i i
i
dV dS =

} }
u f u T u P

(24)
The total potential for the general elastic body shown in Fig.1.1 is
T
1
T T T
2
i i
i
V V S
dV dV dS [=

} } }
u f u T u P o e
(25)
Prof .N. Siva Prasad, Indian Institute of Technology Madras
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Principle of Minimum Potential Energy
For conservative systems, of all the kinematically admissible
displacement field, those corresponding to equilibrium extremize the
total potential energy. If the extremum condition is a minimum, the
equilibrium state is stable.
Kinematically admissible displacements are those that satisfy the
single-valued nature of displacements and the boundary conditions.

Prof .N. Siva Prasad, Indian Institute of Technology Madras
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Example 1

Fig. 5 shows a system of springs. The total potential energy is given by
Fig. 5 System of springs
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Fixed
support

Fixed
support
F
1

F
3

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2 2 2 2
1 2 3 4 1 1 3 3 1 2 3 4
1 1 1 1
2 2 2 2
k k k k F q F q = o + o + o + o
[
(26)
where are extensions of the four springs. Since
1 2 3 4
, , , and o o o o
1 1 2 2 2 3 3 2 4 3
( ), , ( ), q q q q q and q o = o = o = o = substituting for oi we can write H as
( ) ( )
2
2 2
1 1 2 2 3 3 2 4 1 1 3 3 2 3
2
1 1 1 1
2 2 2 2
k q q k q k q q k q F q F q = + + +
[

(27)
where q
1
,q
2
,andq
3
are the displacements of nodes 1,2, and 3, respectively.

Prof .N. Siva Prasad, Indian Institute of Technology Madras
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For equilibrium of this three degrees of freedom system, we need to
minimize with respect to q
1
, q
2
, and q
3
. The three equations are given
by
[
0 1, 2,3 i
q
i
c
[
= =
c
(28)
which are
0
1 1 2 1
1
0
1 1 2 2 2 3 3 2
2
0
3 3 2 4 3 3
3
k q q F
q
k q q k q k q q
q
k q q k q F
q
| |
|
\ .
| | | |
| |
\ . \ .
| |
|
\ .
c
[
= =
c
c
[
= + =
c
c
[
= + =
c
(29)
Prof .N. Siva Prasad, Indian Institute of Technology Madras
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These equilibrium equations can be put in the form of matrix, Kq=F as
follows:
0
1 1 1 1
0
1 1 2 3 3 2
0
3
3 3 3 4
k k q F
k k k k k q
F
q k k k
(

(

(


(
` `
(

(

(

)
)

+ + =
+
(30)
Prof .N. Siva Prasad, Indian Institute of Technology Madras
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One dimensional problems
In one dimensional problems, the stress, strain, displacement,
and loading depends only on the variable x
( ) u x = u
( ) x o o =
( ) x c c = ( ) T x = T
( ) f x = f
The stress-strain and strain-displacement relations are
E o c =
du
dx
c =
The loading consists of three types
- body force f
-traction force T
-point load P
i

One dimensional problems
Prof .N. Siva Prasad, Indian Institute of Technology Madras
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X
P
2

P
1

f
T
One dimensional bar loaded by traction, body and point loads
One dimensional problems contd..
Prof .N. Siva Prasad, Indian Institute of Technology Madras
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Finite element modeling of the bar
.
.
X
.
X
1
4
3
2
1
2
5
3
4
.
.
.
.
One dimensional problems contd..
Prof .N. Siva Prasad, Indian Institute of Technology Madras
.
32
Co-ordinates and shape functions
Consider a typical finite element in the local coordinate system (Fig a) we
define a natural co-ordinate system, denoted by
1
2 1
2
( ) 1 x x
x x
=

1 = +
1 2
1 =

X
1
X

X
2
e
1 2
1
2
1
( )
2
1
( )
2
N
N

=
+
=
1
1
N
1
N
2
1 = 1 = + 0 =
1
0
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Fig.a
Fig.b
e
One dimensional problems contd..
33
Linear interpolation
e e
u
1
u
2
q
1
q
2
u
unknown

u
linear

1 2
1
2
Linear displacement field within the element can be written in terms of the nodal
Displacement q
1
and q
2
as
1 1 2 2
u N q N q = +
In matrix notation
u Nq =
The transformation from x to can be written in terms of N
1
and N
2
as
1 1 2 2
x N x N x = +
Isoparametric formulation

Prof .N. Siva Prasad, Indian Institute of Technology Madras


| |
| |
1 2
1 2
,
,
T
N N N
q q q
=
=
where
One dimensional problems contd..
34
The general expression for the potential energy
1
2
T T T
i i
i
Adx u fAdx u Tdx u P o c [ =

} } }
Since the continuum has been discretized into finite elements, the expression for
Potential energy becomes
1
2
T T T
i i
e e e i
Adx u fAdx u Tdx QP o c [ =

} } }
The last term above assumes that point load P
i
are applied at the nodes. This
assumption makes the present derivation simpler with respect to notation, and
is also a common modeling practice

T T
e i i
e e e i
e
U u fAdx u Tdx QP [ =

} }
where
1
2
T
e
U Adx o c =
}
is the element strain energy
Prof .N. Siva Prasad, Indian Institute of Technology Madras
One dimensional problems contd..
35
Element stiffness matrix
Consider the strain energy form
1
2
T
e
U Adx o c =
}
Substituting for and into the above yields
EBq o =
Bq c =
1
[ ]
2
T T
e
e
U q B EBAdx q =
}
In the finite element model, the cross sectional area of element e,denoted by A
Is constant. Also , B is a constant matrix, further the transformation from x to
yields
2
e
l
dx d =
where
1 1 s s
L
e
is the length of the element
Prof .N. Siva Prasad, Indian Institute of Technology Madras

One dimensional problems contd..


36
The element strain energy Ue is now written as
1
1
1
2 2
T T e
e e e
l
U q A E B B d q

(
=
(

}
Where E is the youngs modulus of element and by using
1
1
2 d

=
}
| |
2
1
1 1
1 1
1 2
T
e e e e
e
U q Al E q
l


=
`
)
Which results in
1 1
1
1 1 2
T
e e
e
e
A E
U q q
l

(
=
(


The above equation is of the form
1
2
T e
e
U q k q =
Where the element stiffness matrix k
e
is given by
1 1
1 1
e e
e
e
A E
k
l

(
=
(


Prof .N. Siva Prasad, Indian Institute of Technology Madras
One dimensional problems contd..
37
The element body force term appearing in the total potential energy
is considered first. substituing u = N
1
q
1
+ N
2
q
2
we have
T
e
u fAdx
}
1 1 2 2
( )
T
e
e
u fAdx A f N q N q dx = +
} }
A and f are constant within the element and were consequently brought outside
The integral. the above equation can be written as
1
2
e
e T T
e
e
e
A N dx
u fAdx q
A f N dx


=
`

)
}
}
}
The integrals of the shape functions above can be readily evaluated
by making the substitution
2
e
l
dx d
| |
=
|
\ .
1
1
1
1
2
1
1
2 2 2
1
2 2 2
e e
e
e e
e
l l
N dx d
l l
N dx d

= =

= =
} }
} }
The body force term in reduces to
1
1 2
e
e e
Al f
f

=
`
)
Force vector
Prof .N. Siva Prasad, Indian Institute of Technology Madras
One dimensional problems contd..
38
Traction force vector
The element traction force term appearing in the total potential energy
is now considered we have
( )
1 1 2 2
T
e e
u Tdx N q N q Tdx = +
} }
Since the traction force T is constant within the element, we have
1
2
e T T
e
e
T N dx
u Tdx q
T N dx


=
`

)
}
}
}
Then the element traction force vector,T
e
is given by
1
1 2
e
e
Tl
T

=
`
)
Prof .N. Siva Prasad, Indian Institute of Technology Madras
One dimensional problems contd..
39
The x coordinate system is mapped on to a coordinate system which is
given by the transformation
3
2 1
2( ) x x
x x

1
2
3
1
( ) (1 )
2
1
( ) (1 )
2
( ) (1 )(1 )
N
N
N



=
= +
= +
1 = +
X

1 2
1 =

0 =
1
2
3
3
Quadratic shape functions
Prof .N. Siva Prasad, Indian Institute of Technology Madras
One dimensional problems contd..
40
Quadratic shape functions contd..
The displacement field within the element is written in terms is written in terms
Of the nodal displacement as
1 1 2 2 3 3
u N q N q N q = + +
or
u Nq =
1
3
2
q
1
q
2

q
3

u
1
1
1
N
1

N
2

N
3

1 = + 1 =
0 =
1
2
3
1
2
3
1
3
2
Prof .N. Siva Prasad, Indian Institute of Technology Madras
One dimensional problems contd..
41
Two dimensional problems
The displacement vector u is given as
| |
T
u u v =
Where u and v are the x and y components of u, respectively the stresses and
Strains are given by
T
x y xy
T
x y xy
o o o o
c c c c
( =

( =

x
y
T
v
u
U=0
The fig. representing the two dimensional problem
in a general setting, the body force, traction vector,
And elemental volume are given by
T
x y
T
x y
f f f
T T T
( =

( =

and
dv tdA =
The strain displacement relations are given by
T
u u u v
x y y x
c
( | | c c c c
= +
( |
c c c c
\ .
p
x

p
y

o
Prof .N. Siva Prasad, Indian Institute of Technology Madras
42
Constant strain triangle
Area coordinates
the shape functions can be physically represented
By area coordinates N
1
,N
2
,N
3
1
2
3
(x,y)
A
3
A
2
A
1
T
U=0
The independent shape functions are conveniently reperensented by the pair
1
2
3
1
N
N
N

q
q
=
=
=
1 2 3
1 N N N + + =
1
1
2
2
3
3
A
N
A
A
N
A
A
N
A
=
=
=
Finite element Discretization
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Two dimensional problems contd..
43
Isoparametric representation
The displacements inside the elements are now written using the shape function
And the nodal values of the unknown displacements
1 1 2 3 3 5
1 2 2 4 3 6
u N q N q N q
v N q N q N q
= + +
= + +
The relations can be expressed in matrix form by defining a shape function
1 2 3
1 2 3
0 0 0
0 0 0
N N N
N
N N N
(
=
(


o
or
= u Nq
For the triangular element, the coordinates x,y can be also be represented
by the nodal Coordinates by using the same shape functions
1 1 2 2 3 3
1 1 2 2 3 3
x N x N x N x
y N y N y N y
= + +
= + +
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Two dimensional problems contd..
44
u u x u y
x y
u u x u y
x y

q q q
c c c c c
= +
c c c c c
c c c c c
= +
c c c c c
u x y
u
x
u
u x y
y

q q q
c c c
( c

(

c c c
c
(
=
` `
c
c c c
(

(
c
c c c
)
)


x y
x y

q q
c c
(
(
c c
(
=
c c (
(
c c

J


In evaluating strains ,the partial derivatives of u and v are to be taken with
respect to X and y coordinates, these derivatives can be expressed in terms
local coordinates by
Make use of chain rule
Where the 2 X 2 matrix is denoted as the Jacobian of transformation
13 13
23 23
x y
x y
(
=
(

J


Strain displacement relation
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Two dimensional problems contd..
45
u
u
x
u
u
y

c
c



c
c
=
` `
c
c

c
c
)
)
I
J
23 13
23 13
1
det
y y
x x


(
=
(


I
J
J

x
13 23 23 13
det x y x y = J
1
det
2
A = J
Where J is the inverse of the Jacobian
Strain displacement relation contd..
and
The area of the triangle
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Two dimensional problems contd..
46
Plane stress
t
0
0
0
z
yz
xz
o
o
o
=
=
=
0
z
c =
y
x
z
The constitutive relation
2
1 0
1 0
1
1
0 0
2
x x
y x
xy xy
E
o v c
o v c
v
t v
(
(
(
=
` `
(

) )
(

Prof .N. Siva Prasad, Indian Institute of Technology Madras
Two dimensional problems contd..
47
0
z
o =
0
0
0
z
xz
yz
c
c
c
=
=
=
Prof .N. Siva Prasad, Indian Institute of Technology Madras
z
The constitutive relation
1 0
1 0
(1 )(1 2 )
1 2
0 0
2
x x
y x
xy xy
E
o v v c
o v v c
v v
t v
(
(
(
=
` `
(
+

(

) )
(

Two dimensional problems contd..
Plane strain
y
x
48
Dynamic analysis
When loads are suddenly applied,
The mass and acceleration effects are come in to picture
Lagrangian
L T = [ T Kinetic energy
[
Potential energy
Hamilton Princible
For an arbitrary time interval from t1 to t2,the state of motion of a body extremizes the
functional
2
1
t
t
I Ldt =
}
If L can be expressed in terms of the generalized variables
1 2 3 4
, , , ,..... ,
n
q q q q q
- - - - -
where
i
i
q
q
t
-
c
=
c
Then the equations of motions are given by
0
i i
d L L
dt q q
| | c c
=
|
c c
\ .
i=1 to n
Prof .N. Siva Prasad, Indian Institute of Technology Madras
49
1 1
, x x
-
2 2
, x x
- m2
m1
The kinetic energy and potentially energy are given by
2 2
1 1 2 2
2 2
1 1 2 2
1 1
2 2
1 1
2 2
T m x m x
k x k x
- -
= +
[ = +
Using and
L T = [
0
i i
d L L
dt q q
| | c c
=
|
c c
\ .
i=1 to n
The equations of motions will be
1 1 1 1 2 2 1
1
1
2 2 2 2 1
2
2
( ) 0
( ) 0
d L L
m x k x k x x
dt x
x
d L L
m x k x x
dt x
x
--
-
--
-
| |
c c
|
= + =
c |
c
\ .
| |
c c
|
= + =
c |
c
\ .
In matrix form
1 1 1 2 2 1
2 2 2 2
2
0 ( )
0
0
m x k k k x
m k k x
x
--
--

+
( (

+ =
` `
( (

)

)
Spring mass system
Stiffness matrix
Mass matrix
Dynamic analysis contd..
50
Systems with Distributed mass
x
z
y
u
v
w
dv
= density
v
The kinetic energy
The velocity vector of point at x with components
In the finite element method,we divide the body
into elements,and in each element
and
1
2
T
v
T u u dv
- -
=
}
, , u v w
- - -
u Nq =
u N q
- -
=
The kinetic energy T
e
1
2
1
2
T
v
T
v
T u u dv
T q N Ndv q

- -
- -
=
(
=
(

}
}
Mass matrix
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Dynamic analysis contd..
51
Scalar field problems
General Helmholtz equation given by




is the field variable that is to be determined
Q is the heat source or sink




( ) ( ) ( ) 0
x y z
k k k Q
x x y y z z
| | |
|
c c c c c c
+ + + + =
c c c c c c
( , , ) x y z | | =
Prof .N. Siva Prasad, Indian Institute of Technology Madras
52
Thermal problems
x y
T T
q k q k
x y
c c
= =
c c

T=T(x,y) is a temperature field in the medium

q
x
and q
y
are the components of the heat flux ( W/m2 )

k is the thermal conductivity ( W/m

c )

,
T T
x y
c c
c c
are the temperature gradients along x and y

Fouriers law for two dimensional heat flow is given by
Prof .N. Siva Prasad, Indian Institute of Technology Madras
53
One dimensional steady state heat conduction
Governing Equation






Boundary conditions

The boundary conditions are mainly of three kinds
Specified temperature
Specified heat flux (or insulated)
Specified convection
( ) 0
d dT
k Q
dx dx
+ =





QAdx

x dx
Left face
Right face
x
Prof .N. Siva Prasad, Indian Institute of Technology Madras
54
Ex.2
The inside surface of a wall is
insulated and outside is a convection
surface
0 0
( )
x
x L L
T T
q h T T
=
=
=
=
One dimensional steady state heat conduction
The boundary conditions for this problem are

(Specified)
L
, h T

L
T
0
T Ex. 1
Consider the wall of a tank
containing a hot liquid at temperature
T
0
, with an air stream temperature T


passed on the outside, maintaining a
wall temperature of T
L
at the
boundary as shown in fig below

, h T



x
q=0(insulated)
L
T
L
0
0
x
q
=
= ( )
x L L
q h T T
=
=
Prof .N. Siva Prasad, Indian Institute of Technology Madras
55
Heat Dissipation
Hot gases
1
2 3 4
, h T

0
T
One dimensional steady state heat conduction
Finite element model
Prof .N. Siva Prasad, Indian Institute of Technology Madras
56
Two dimensional steady state heat conduction
Governing equation



( ) ( ) 0
T T
k k Q
x x y y
c c c c
+ + =
c c c c






S
T
: T=T
0

S
q
: q
n
=q
0

S
c
: q
n
=h(T-T

)

Boundary conditions

Boundary conditions are of three types

specified temperature T=T
0


specified heat flux q
n
=q
0
on S
q

convection q
n
=h(T-T

)on S
c
Prof .N. Siva Prasad, Indian Institute of Technology Madras
57
Two dimensional steady state heat conduction
A
A
Section A-A
Heat Transformation in chimney
Example 1
Prof .N. Siva Prasad, Indian Institute of Technology Madras
58
Example 2
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Two dimensional steady state heat conduction
59
0
c
0
T c o = A
0
( ) E c c c =
0 0 0 0
1 1
( ) ( ) ( )
2 2
T
u E o c c c c c c = =
0 0
1
( ) ( )
2
T
L
U E Adx c c c c =
}
Thermal stresses
If the change in temperature is T(x), then the strain due to this temperature
Change is known as initial strain, , given as
o
T A
is coefficient of thermal expansion
implies raise in temperature
The stress-strain relation in the presence of initial strain is given by
strain energy per unit volume
Total strain energy
Prof .N. Siva Prasad, Indian Institute of Technology Madras
60
1
0
1
2
e T
e
e e
l
E A d u c

=
}
B
Thermal stress contd..
c = Bq
Noting that ,we get

0
d
d
[
=
Q
For minimization of the functional the necesssry condition
1 1
0
1 1
2
0
1
( )
2 2 2
1
2 2
T T T T
e e
e e e e
e e
e
e e
e
l l
U E A d E A d
l
E A
c
c

=
+

} }

q B B q q B
Stiffness matrix
Thermal load vector
1
0 0
1
1
( ) ( )
2 2
T
e
e e
e
l
U A E d c c c c

}
For a structure modeled using one-dimensional linear elements, the above
equation becomes
Constant term
Prof .N. Siva Prasad, Indian Institute of Technology Madras
61
After solving the finite element equations KQ=F for the displacements Q
The stress in each element
( )
e e e
e
u = + + +

F f T P
( ) E T o o = A Bq
The temperature load vector can be assembled along with the body force, traction
force, and point load vectors to yield the global load vector F, for the structure.
2 1
1
1
e
e e e
E Al T
x x
o
u

A
=
`

)

By substituting
| |
2 1
1
1 1
x x
=

B
0
T c o = A and
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Thermal stress contd..
62
Types of Elements
One dimensional elements

1. Beam (axial)

2. Beam (bending)

3. Pipe
Prof .N. Siva Prasad, Indian Institute of Technology Madras
63
Two dimensional elements

1. Triangular
inplane
bending

2. quadrilateral
inplane
bending
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Types of Elements
64
Three dimensional elements

1. brick

2. Tetrahedral

Prof .N. Siva Prasad, Indian Institute of Technology Madras
Types of Elements
65
Modeling
Element type must be consistent

Finer mesh near the stress gradient

Extremely fine mesh when forces to be applied near the stress
concentration areas such as fillets

Uniform change in stress between adjacent elements

Better aspect ratio


Prof .N. Siva Prasad, Indian Institute of Technology Madras
66
Modeling (contd)
Gross element distortion should be avoided

Adjoining elements must share common nodes and common
degrees of freedom
45
0

15
0

Prof .N. Siva Prasad, Indian Institute of Technology Madras
67
Debugging of FE models
Geometry

Material properties

Applied forces

Displacement constraints

Prof .N. Siva Prasad, Indian Institute of Technology Madras
68
Common symptoms and their possible causes

Symptoms


Causes
Excessive deflection, but
anticipate stress


Excessive deflection and
excessive stress


Internal discontinuity in stress and
deflection

Youngs modulus too low,
missing nodal constraints


Applied force too high,
nodal coordinates incorrect,
force applied at wrong nodes

Force applied at wrong nodes,
missing or double internal element
Prof .N. Siva Prasad, Indian Institute of Technology Madras
69

Symptoms


Causes

Discontinuity along boundary



Higher or lower frequency than
anticipated
-Static deflections, O.K.
-Static deflection not O.K.

Internal gap opening up in model
under load, stress discontinuity
Missing nodal constraint,
force applied at wrong node


Density incorrect
Youngs modulus incorrect



Improper nodal coupling
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Common symptoms and their possible causes
70
Dynamic analysis
Modal analysis - Natural frequency and mode shapes

Harmonic analysis - Forced response of system to a sinusoidal
forcing

Transient analysis - Forced response for non-harmonic loads
(impact, step or ramp forcing etc.)

Prof .N. Siva Prasad, Indian Institute of Technology Madras
71
Substructure
Rules for substructure

A substructure may be generated from individual elements or other
substructures

Master nodes to be retained to be identified

Nodal constraints will be retained in all subsequent uses of the
substructure

Along a substructure boundary that will be used for connection to
the rest of the global model, all nodes must be retained as master
nodes

Cost effective

Prof .N. Siva Prasad, Indian Institute of Technology Madras
72
Guidelines for selection of dynamic degree of
freedom (DDOF)
No. of the DOF must be 2 times highest mode of interest
No. of reduced modes will be equal to the number of DDOF so that
only bottom half of the calculated modes should be considered
accurate
DDOF should be placed in areas of large mass and rigidity
DDOF should be distributed in such a way as to anticipate mode
shapes
DDOF be selected at each point of dynamic force application
DDOF must be used with gap elements
For plate type elements emphasise DDOF in out of plane direction

Prof .N. Siva Prasad, Indian Institute of Technology Madras
Common Errors in Finite Element Analysis
Idealization error Discretization error
Idealization Error
Posing the problem
Establishing boundary conditions
Stress-strain assumption
Geometric simplification
Specifying simplification
Specifying material behaviour
Loading assumptions
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Error - 1
Discretization Error

Imposing boundary conditions
Displacement assumption
Poor strain approximation due to element distortion
Feature representation
Numerical integration
Matrix ill-conditioning
Degradation of accuracy during Gaussian elimination
Lack of inter-element displacement compatibility
Slope discontinuity between elements
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Error - 2
SOURCES OF NONLINEARITIES
Geometric

Material

Force Boundary Conditions

Displacement Boundary Conditions
Prof .N. Siva Prasad, Indian Institute of Technology Madras
GEOMETRIC NONLINEARITY
Physical source
Change in geometry as the structure deforms is taken into account
in setting up the strain displacement
and equilibrium equations.

Applications
1. Slender structures in aerospace, civil and mechanical
engineering applications.
2. Tensile structures such as cables and inflatable membranes.
3. Metal and plastic forming.
4. Stability analysis of all types.
Prof .N. Siva Prasad, Indian Institute of Technology Madras
GEOMETRIC NONLINEARITY CONTD..
Mathematical source
Strain-displacement equations:
e = Du (2.1)
The operator D is nonlinear when finite strains (as
opposed to infinitesimal strains) are expressed in terms
of displacements.

Internal equilibrium equations:
b = D (2.2)

In the classical linear theory of elasticity, D = DT is the
formal adjoint of D, but that is not necessarily true if
geometric nonlinearities are considered.

Prof .N. Siva Prasad, Indian Institute of Technology Madras
GEOMETRIC NONLINEARITY CONTD..
Large strain
The strains themselves may be large, say over 5%.
Ex: rubber structures (tires, membranes)

Small strains
but finite displacements and/or rotations. Slender
structures undergoing finite displacements

Rotations
although the deformational strains may be treated
as infinitesimal.
Example: cables, springs

Prof .N. Siva Prasad, Indian Institute of Technology Madras
Linearized prebucking.
When both strains and displacements may be treated as
infinitesimal before loss of stability by buckling.These may
be viewed as initially stressed members.

Example:
Many civil engineering structures such as buildings and stiff
(non-suspended) bridges.
GEOMETRIC NONLINEARITY CONTD..
Prof .N. Siva Prasad, Indian Institute of Technology Madras
MATERIAL NONLINEARITY
Physical source
Material behavior depends on current deformation state and
possibly past history of the deformation.
Other constitutive variables (prestress, temperature, time,
moisture, electromagnetic fields, etc.) may be involved.

Applications
Structures undergoing

Nonlinear elasticity
Plasticity
Visco-elasticity
Creep, or inelastic rate effects.
Prof .N. Siva Prasad, Indian Institute of Technology Madras
MATERIAL NONLINEARITY CONTD..
Mathematical source
The constitutive equations that relate stresses and
strains. For a linear elastic material

= Ee
where the matrix E contains elastic moduli.

Note:
If the material does not fit the elastic model,
generalizations of this equation are necessary, and a
whole branch of continuum mechanics is devoted to the
formulation, study and validation of constitutive
equations.
Prof .N. Siva Prasad, Indian Institute of Technology Madras
MATERIAL NONLINEARITY CONTD..
The engineering significance of material nonlinearities varies greatly
across disciplines.
Civil engineering deals with inherently nonlinear materials such as
concrete, soils and low-strength steel.
Mechanical engineering creep and plasticity are most important,
frequently occurring in combination with strain-rate and
thermal effects.
Aerospace engineering material nonlinearities are less important
and tend to be local in nature (for example, cracking and
localization failures of composite
materials).


Prof .N. Siva Prasad, Indian Institute of Technology Madras
Material nonlinearities may give rise to very complex
phenomena such as path dependence, hysteresis,
localization, shakedown, fatigue, progressive failure.
The detailed numerical simulation of these phenomena
in three dimensions is still beyond the capabilities of the
most powerful computers.

Prof .N. Siva Prasad, Indian Institute of Technology Madras
MATERIAL NONLINEARITY CONTD..
FORCE BC NONLINEARITY
Physical Source
Applied forces depend on deformation.
Applications
The most important engineering application concerns pressure loads
of fluids.
Ex:
1. Hydrostatic loads on submerged or container structures;
2. Aerodynamic and hydrodynamic loads caused by the motion of
aeriform and hydro form fluids (wind loads, wave loads, and drag
forces).

Prof .N. Siva Prasad, Indian Institute of Technology Madras
DISPLACEMENT BC NONLINEARITY
Physical source
Displacement boundary conditions depend on the
deformation of the structure.
Applications
The most important application is the contact problem,
in which no-interpenetration conditions are enforced on flexible
bodies while the extent of the contact area is unknown.

Non-structural applications of this problem pertain to the more
general class of free boundary problems,

example: ice melting, phase changes, flow in porous media.

The determination of the essential boundary conditions is a key
part of the solution process.
Prof .N. Siva Prasad, Indian Institute of Technology Madras
86
Some solution method

For a time independent problem
[K]{D}={F}
For a linear analysis [K] and {R} are independent of [D].
For nonlinear analysis [K] and {R} are regarded
as function of {D}

Consider [K] is a function of {D} and can be computed
for a given {D} Consider a nonlinear spring in Fig 1

Spring stiffness [K]=K
0
+K
N

K
0
=constant term
K
N
=depends on deformation

(K
0
+K
N
)u=P

Where u=displacement
P=load And K
N
=f(u) and depends on [D]

Note: 1.when K
N
is known in terms of u,P can be calculated in terms of u
2.Explicit solution for u is not available
3.u can be determined by iterative methods
K
U
P
u
P
Hardening
K
N
>0
Softening
K
N
<0
K
N
=0
Fig 1
87
1
0
A
P
u
K
=
2
0 1
( ( ))
A
P
u
K f u
=
+
1 1 1
1 0 2 0 1 1 0
, ( ) ,......, ( )
A N A i Ni A
u k p u k k p u k k p

+
= = + = +
Direct substitution

Let K
N
<0 (softening spring
P
A
is the load applied
Assume K
N
=0 first iteration
U
A
=displacement produced for the first iteration

Use u
1
to compute the new stiffness. K
0
+K
N1
=K
0
+f(u)

Writing symbolically

This calculations are interpreted graphically in Fig 2.2
Note:
1.Approximate stiffness K
0
+K
Ni
can be regarded as secants of the actual curve
2.After several iterations, the secant stiffness=K
0
+K
N
3.stiffness=P
A
/U
A
u=u
A
is closely approximated
u
P
u
1
u
2
u
3

1
2
3
a
b
c
K
0

Slope=K
0
-K
N1

FEA of Engine block for noise
and vibration
Case Studies (Automotives)
FE model of cylinder block
FE Model of oil sump
Main bearing forces
Second mode of vibration
FEA of single cylinder diesel
engine crankshaft
Crank shaft nomenclature
Solid model of crank shaft with flywheel
and balance weights
Meshed model
Element used: Tetrahedron
Alternate bending
stress
Alternate shear stress
Main bending stress
Main shear stress
Tractor Rear Axle
Wheel Track
Flange to Flange
Wheel Stand out
Wheel
To
Fender
clearance
Fender
ROPS
Only Axle housing and Axle Shaft Modifications are considered in the project
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Tractor-3
Packaging Requirements
Flange to flange distance of 1524 mm (60)

Std wheel track of 1320 mm (52)

Fender to fender distance like existing model
To take care of the 3 point linkage fouling with the Fender

Wheel to fender clearance of 60 mm

Wheel stand out from fender should not be more than 40 mm

Roll Over Protective Structures (ROPS) fitment suitability
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Tractor-4
Fender
and
ROPS
mtg
details
ROPS
fitment
Suitabilit
y
Fender
to
Fender
distance
Wheel
Standou
t
Fender
Wheel
Clearan
ce
3 point
Linkage
clearanc
e
Packaging with FENDER,ROPS
And 3Pt Linkages
Existing Base plate of the ROPS has to be modified.
Fender to Fender Distance is important for 3 pt linkage clearance
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Tractor-7
Packaging
Fender and
ROPS mtg
details
ROPS
fitment
Suitability
Fender to
Fender
distance
Wheel
Standout
Fender
Wheel
Clearance
3 point
Linkage
clearance
Modifications carried out
On axle housing to get all the
Required features.
Length of the housing modified
3 or 4 slots tried out
Position of slots modified.
Tractor-8
Finalized Model of the Modified Housing
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Tractor-10
Constraints in Modified Housing Design
Need for making use of the existing fixtures, gauges
and machine tools, limits the modifications.
A New housing without all these limitations, but
meeting all vehicle requirements were also
designed.

It weighs just 55 kg against the original housing
weight of 70.5kg
New Housing
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Tractor-11
FEA of the Axle housings
All three Axle housings, Existing Axle housing,
Modified Axle housing and New Axle Housing were
subjected for FEA as per Test Spec Loading.

If, the stress levels of the latter two housings are less
than the Existing housing then the design is assumed
to be safe

Since, there is no failure in the Existing axle housing so
far.
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Tractor-12
Meshing Details
Parameter Existing
axle
housing
Modified
axle
housing
New axle
housing
Number of
nodes
172268 245479 295685
Number of
elements
94502 140515 168000
Weight, kg 70.5 62 55
Solver : ANSYS
Meshing : ANSYS
Element Type : Tetrahedron
Element Name : SOLID 187
Existing Axle Housing Modified Axle Housing New Axle Housing
Tractor-13
Vertical Loading condition
Load Set 1 Load Set 2
Loading Condition
Hogging Loading
condition
Tractor-14
Normal Stress plot of Existing axle housing with Load set 1
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Tractor-15
Normal Stress plot of Modified axle housing with Load set 2
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Tractor-18
Normal Stress plot of Modified axle housing with Hogging load
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Tractor-22
Loading
condition
Maximum stress
condition
Normal Stress in Axle housing, MPa
Existing Modified New
Load set 1 Tensile 321 143 170
Load set 1 Compressive 112 32 19
Load set 2 Tensile 632 281 335
Load set 2 Compressive 221 64 37
Comparison of normal stresses under vertical condition.
Loading
condition
Maximum stress
condition
Normal Stress in Axle housing, MPa
Existing Modified
Hogging Tensile 216 103
Hogging Compressive 32 16.5
Comparison of normal stresses under hogging.

Prof .N. Siva Prasad, Indian Institute of Technology Madras
Tractor-23
FEA Results
In all conditions in Vertical loading, both modified and
New axle housing stresses are far less than the
Existing axle housing.

Even in Hogging, Modified axle housing stresses are
lesser than the Existing axle housing.

Hence, it can be a safe design having same reliability
like the existing housing.

Prof .N. Siva Prasad, Indian Institute of Technology Madras
Tractor-24
(a) (b)
New Axle Housing (55 kg)
Modified Axle Housing (62 kg)
Final design of Axle housings
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Tractor-25
FEA for Automotive application
CLUTCH
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Clutch - 1
Axial spring clutch system in a truck with
ceramic clutch disk
Face Plate
Clutch Plate
Pressure Plate
Flywheel
Bent Clutch Disc
Face Plate Back Plate
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Clutch - 2
Problem Definition
Due to extreme temperatures during clutch operation at
interface, there is occurrence of pressure plate warpage.
This leads to clutch failures

Frictionally induced Thermo-mechanical instability causes
breakdown of physical properties hence inducing warpage.

The problem is a contact problem which is transient and
non linear.


Prof .N. Siva Prasad, Indian Institute of Technology Madras
Clutch - 3
Material Properties
S.No Property Grey Cast Iron
97% Alumina
ceramic
Units
1. Density 7.34 *10 3.69 *10 kg/m
2. Modulus of elasticity 124 300 GPa
3.
Thermal expansion (20
C)
9.0*10-6 7.3*10-6 C
4. Specific heat capacity 840 880 J/(kg*K)
5. Thermal conductivity 53.3 18 W/(m*K)
The two rotating discs were - Grey cast iron sliding against, alumina. The
following properties were considered.
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Clutch - 4
Analysis parameters
S.No Parameter Definition
1. Element type Element with both structural and thermal capability
2. Analysis type Non-linear - Geometric Parameter is included.
3. No. of Sub-steps Multiple sub-step -Progressive time step Starting from 0
to 0.75 sec with sub-step of 0.005 sec
4. Pressure/ Angular Velocity Pressure and Angular velocity simultaneously varying
5. Coupling Rigid element coupling with master and slave nodes
6. Averaging method Multiple facets - A single element divided into sub
elements at the mid-nodes. Result is the average of the
sub elements.
Element with mid-side node
Solid 226
Time varying Pressure / angular Velocity
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Clutch - 5
FE Model / Boundary conditions
Master node defined at center with
inner nodes as slave nodes. Rotational
velocity given at the Master Node
Mesh using Solid 226
Contact Pair Creation at interface
CONTA174 upper nodes of lower disk
TARGE170 Lower nodes of upper disk
All DOF
constrained for
stationary disk
at bottom end
Pressure applied at
the rotating disk
surface
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Clutch - 6
Comparison with Du & Fash Model and
simulation
Top surface
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Clutch - 7
Bottom surface
Anti-symmetric w.r.t top
surface
Comparison with Du & Fash Model and
simulation
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Clutch - 8
Top surface
Comparison with Du & Fash Model and
simulation
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Clutch - 9
Extension of Quarter disk to Annular Disk
Focal hot-spots at Mid-plane
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Clutch - 10
Crashworthiness of a Commercial Vehicle
using Finite Element Method
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Need of crash analysis
Year Road Accidents
(In Thousands)
Persons Killed
(In Thousands)
Persons Injured
(In Thousands)
2004 429.8 92.5 464.6
2003 406.7 86.0 435.1
2002 407.5 84.7 408.7
2001 405.6 80.9 405.2
2000 391.4 79.8 399.3
1999 386.4 82.0 375.0
1998 385.0 79.9 390.7
1997 373.7 77.0 378.4
1996 371.2 74.6 369.5
1995 348.9 70.6 323.2
1994 320.4 64.0 311.5
(Source: Department of Road Transport and Highways, Ministry of Shipping, Road Transport and Highways, Government of India.)
Auto Accident Statistics
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 1
Objectives
To evaluate the occupant response and the
structural damage according to the Federal
Motor Vehicle Safety Standard (FMVSS)
frontal impact regulation and ECE-R29
regulation in accordance with the basic
principles of automotive crashworthiness.

To check the deformation length and the
amount of energy absorbed at high crash
velocities (resulting in less fatal injuries).

Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 2
Finite Element Methods for analysis
The following softwares are used to carryout the analysis:

Modeling
Catia/ Pro -
E
Meshing and Boundary
Conditions
HyperMesh
Solver
LS-DYNA
Post-processing and
viewing the results
HyperView
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 3
Truck Modeling
Mass density (kg/m
3
) 7890
Young's Modulus (GPa) 210
Yield Stress (MPa) 270
Poisson Ratio 0.3
Vehicle Material Properties
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 4
Finite Element Model of the Truck
Number of Parts 157
Number of Nodes 38955
Number of Elements 36539
Number of Quad Elements 33124
Number of Tria Elements 2012
Number of Discrete Elements 10
Ford Truck Vehicle Model Summary
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 5
Load Cases simulated according
to ECE-R29 Regulation
Load Cases Variations
Pendulum striking the truck without constraining the cabin of the truck.
( kJ)
a. 36
b. 54
Pendulum striking the truck with the back wall of the cabin held to a fixture
( kJ)
a. 36
b. 54
ECE-R29 frontal impact test configuration
(ECE Economic Commission for
Europe)
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 6
Simulation results for 36 kJ of energy
transferred from pendulum
Displacement contour plot for
pendulum transferring 36 kJ of energy.
% Reduction in occupant space = 2 %
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 7
Simulation results for 54 kJ of energy
transferred from pendulum
Displacement contour plot for
pendulum transferring 54 kJ of
energy.
% Reduction in occupant space = 5 - 6%
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 8
Simulation results for 36 kJ of energy
transferred with cabin constrained
Displacement contour plot for 36
kJ energy transferred, cabin
constrained
% Reduction in occupant space = 7 - 8%
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 9
Simulation results for 54 kJ of energy
transferred with cabin constrained
Displacement contour plot for 54
kJ energy transferred, cabin
constrained
% Reduction in occupant space = 24 - 26%
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 10
Load Cases simulated according to
FMVSS -208 Regulation
Load Cases Variations
Truck hitting a rigid wall with full head on collision (km/hr) a. 36
b. 54
Truck hitting a rigid wall with partial overlap (km/hr) a. 36
b. 54
c. 72
Truck hitting the wall obliquely at 30
o


(km/hr) 36
Partial overlap test configuration Oblique Impact test configuration
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 11
Simulation results for head-on collision with
truck at a speed of 36 kmph
Displacement contour for head-on collision at a
speed of 36km/hr
% Reduction in occupant space = 11 - 13%
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 12
Simulation results for head-on collision with
truck at a speed of 54 kmph
Displacement contour plot for head-on
collision at a speed of 54km/hr
% Reduction in occupant space = 28 - 32%
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 13
Simulation results for partial overlap with
truck at speed of 36 kmph
Displacement contour plot for partial overlap at
a speed of 36 km/hr
% Reduction in occupant space = 14 - 16%
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 14
Simulation results for partial overlap with
truck at speed of 54 kmph
Displacement contour plot for partial overlap at
a speed of 54 km/hr
% Reduction in occupant space = 32 - 34%
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 15
Simulation results for partial ovelap with
truck at speed of 72 kmph
Displacement contour plot for partial overlap at
a speed of 72 km/hr
% Reduction in occupant space = 43 - 45%
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 16
Simulation results for oblique collision at
an angle of 30 degrees at 36 kmph
Displacement contour plot for impact at 30
degree at a speed of 36 km/hr
% Reduction in occupant space = 17 - 18%
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 17
Simulation Results - Acceleration response
Acceleration response of front axle for head-on collision at a speed of
54km/hr
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Crash - 18





144
Drum brakes are used to control the speed of vehicles or to stop
them by friction caused by set of pads
Externally contracting brakes are extensively used for
locomotives
When brakes are applied, high amount of kinetic energy is
transformed into thermal energy in short periods
Present work is intended at predicting the temperature rise during
the process of braking, deceleration and stop time
Coupled field finite element analysis of internally
expanding and externally contracting brakes
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Brake - 1





145
Objectives

Estimation of the contact pressure between brake liner
and counter body (drum/wheel)
Estimation of temperature distribution using coupled field
(structural-thermal) finite element method
Comparison of Finite element analysis results with
experimental values for externally contracting brakes
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Brake - 2





146
Average contact
pressure
(MPa)
Movement of the floor
Present
analysis
Reference
Leftward 1.001911 0.941538
Rightward 8.598652 9.663158
0
4
8
12
16
20
0 6 12 18 24 30
Distance from left end (mm)
C
o
n
t
a
c
t

p
r
e
s
s
u
r
e

(
M
P
a
)
rightward motion of the floor
leftward motion of the floor
Door stop problem is analysed to predict interface pressure
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Brake - 3





147
To validate the methodology for curved surfaces
0
2
4
6
8
10
12
14
0 20 40 60 80 100 120
Lining angle (deg.)
P
r
e
s
s
u
r
e

(
M
P
a
)
Present analysis
Present analysis with chamfer
Day et al. [1]
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Brake - 4





148
A drum brake of commercial truck [4] is analysed to validate the
methodology for the prediction of temperature distribution
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Brake - 5





149
In reference
Thermal analysis is carried out by considering the cross section of
the drum as shown in figure
Heat flux calculated from kinetic energy (KE) loss and applied at
the interface
It represents the assumption of uniform pressure distribution, but it
is not uniform

In present method
Heat flux generated at the interface nodes is implicitly calculated
from contact pressure distribution which is more realistic
compared to the assumption of uniform heat flux to every node on
the inner periphery of the drum considered by reference[2]
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Brake - 6





150
Temperature measurement
Schematic diagram of the dynamometer test facility is shown in
figure
DC Motor
Wheel Fly wheels
Front view Side view of the wheel
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Brake - 7





151
Complete braking is solved in 100 load steps
From the experiment time taken to apply full load is 3.6seconds
20 load steps are used to ramp the load from 0-4.2T
In the 1
st
load step angular displacement corresponding to initial
velocity and a load of F/20 is applied
Analysis is solved
Now the stop time with the average torque of 1
st
load step is
calculated
Then the deceleration is calculated
Velocity after the load step is calculated
Energy available after the load step is determined
In the 2
nd
load step, a force of F/20 is added to the 1
st
load step
load and an angular displacement corresponding to velocity after
the 1
st
load step is applied
Analysis is solved
This procedure is repeated for 20 load steps
After 20 load steps there is no change in the load
Hence there is no change in the deceleration
With the deceleration after 20 load steps is used in the
simulation of remaining 80 load steps
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Brake - 8





152
Pressure distribution at different times during braking is shown in
the graph
Pressure distribution at leading end varies little with the time and is
due to thermal distortion of liner
0
0.5
1
1.5
2
2.5
0 5 10 15 20 25 30 35 40
Lining angle (deg.)
P
r
e
s
s
u
r
e

(
M
P
a
)
contact pressure @ 3.60 sec
contact pressure @ 11.14 sec
contact pressure @ 18.67 sec
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Brake - 9





153
Temperature distribution at a point on the outer periphery of the
wheel is shown in the graph along with the experimental values
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Brake - 10





154
Comparison of the speed calculated by FEA with experimental values
0
50
100
150
200
250
0 3 6 9 12 15 18 21
Time (sec)
S
p
e
e
d

(
r
p
m
)
FEA
Expt
FEA Experiment
Stop time 18.67 18.7
Temperature at the end of the braking process (
0
K)

335.14 332
Comparison of FEA and experimental values
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Brake - 11





155
Rigid beam elements
created from centre to
Brake torque (Nm) after
20 load
steps
40 load
steps
60 load
steps
80 load
steps
100 load
steps
Outer periphery 3507.60 3507.75 3507.53 3507.52 3507.69
Inner periphery 3508.74 3508.82 3508.91 3508.88 3509.20
In another analysis rigid beam elements are created from centre to inner
periphery of the wheel to consider the deformation of wheel in the
analysis
There is no significant variation in the torque by making wheel to behave
as rigid but computational time is less
Hence the wheel can be considered to behave as rigid
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Brake - 12





156
An analysis is carried out to know the variation of pressure
distribution with the velocity
In the first load step shoes are pressed against the drum
In the second load step different angular displacements are applied

Contact pressure doesnt vary with the velocity
0
0.5
1
1.5
2
2.5
0 10 20 30 40
Lining angle (deg.)
P
r
e
s
s
u
r
e

(
M
P
a
)
Second load step 4 radians in 1 sec
Second load step 10 radians in 1 sec
Prof .N. Siva Prasad, Indian Institute of Technology Madras
Brake - 13

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