CAE

By

Dr Rajesh Panda
STO – CAD/CAM – CIPET.
 Definition

Computer Aided Engineering is

defined as the use of computer
system in finding the analytical
solutions to the various Engineering
problems.
 Analytical Solution

An analytical solution is a
mathematical model or expression
that gives the value of the field
variable at any location in the body.
 Numerical Method

For many of the practical problems

an engineer uses numerical
methods to solve the problem and
that provide approximate solution
but acceptable one.
 Numerical Methods

For problems involving complex

shapes, material properties and
complicated boundary conditions, it
is difficult to obtain analytical
solutions.
Three Numerical Methods
available in CAE
1.Functional approximation
2.Functional difference method
3.Finite Element Method (FEM)
and Finite Element Analysis (FEA).
Finite Element Method

Finite Element Method is a most

popular numerical analysis
technique for obtaining approximate
solutions to a wide variety of
engineering problems.
 Finite Element Method

Finite Element Method and Finite

Element Analysis are the two of the
very popular mechanical
engineering applications offered by
existing CAD/CAM systems.
Finite Element Method
It has grown out of the matrix
analysis method used in aircraft
design. This method is based on
dividing a complex shape into small
elements, solving the equilibrium
equations at hand for each element,
and then assembling the element’s
results to obtain the solution to the
original problem.
Finite Element Method

The shape divisions, and the

choice of the element and the
analysis types, are among the
important decisions for the success
of the method.
Finite Element Method

The interpretation of the results of

FEA requires a good understanding
of the principles of engineering such
as linear / nonlinear mechanics,
static and dynamic, heat transfer,
fluid mechanics, etc.
 Advantages of FEM
1. This method is general enough to handle any
complex shape or geometry, any material
property, any boundary conditions and any
loading conditions.
2. FEM fits the analysis requirements of today’s
complex engineering systems and designs.
3. It is an efficient design tool by which designers
can perform parametric design studies by
considering various design cases, analyzing
them and choosing the optimum design.
4. It can solve a wide variety of engineering
problems.
 Finite Element Procedure

1.Creating the finite elements

2.Approximate the solution within an element
3.Develop element matrices and equations
4.Generate the global system matrix equation
5.Solve the unknowns at the nodes
6.Interpret the results
 1.Creating the finite elements
Dividing a continuum in to finite number of non-
overlapping elements.
This is achieved by replacing the continuum by a
set of key points, called nodes, which when
connected properly produce elements. The
collection of nodes and elements forms the finite
element mesh.
A variety of element shapes and types are available.
The larger the number of nodes and elements, the
more accurate the finite element solution, but also
the more expensive, more memory space is needed
to store the finite element model and result, and
more computer time is needed to obtain the solution.
Object (continuum) before mesh
Object (continuum) after mesh
 2.Approximate the solution
within an element
The variation of the unknown (called field
variable) in the problem is approximated
within each element by a polynomial.
Polynomials are usually used to approximate
the solution over an element domain because
they are easy to integrate and differentiate.
The degree of polynomial depends on the
number of nodes per element, number of
unknowns at each node.
 3.Develop element matrices
and equations

Once the nodes and material

properties of a given element are
defined, its corresponding matrices
(Stiffness matrix, mass matrix, etc.)
and equations can be derived.
 4. Generate the global
system matrix equation

The individual element matrices are added

together by summing the equilibrium
equations of the elements to obtain the global
matrices and the system of algebraic
equations. Before solving this system, it must
be modified by applying the boundary
conditions. If boundary conditions are not
applied, wrong results are obtained.
5.Solve the unknowns at the nodes

The global system of algebraic

equations is solved via Gauss
elimination methods to provide the
values of the field variables at the
nodes of the finite element mesh.
Values of the field variables and their
derivatives at the nodes form the
complete finite element solution of the
original continuum problem.
 6. Interpret the results

The final step is to analyze the solution

and results obtained from the previous
step to make design decisions. The
correct interpretation of these results
requires a sound background in both
engineering and FEA.
 ELEMENT TYPES
1. One-dimensional elements: It is made from minimum 2 nodes
to maximum 4 nodes. Line element is an example for one-
dimensional elements. The popular one-dimensional elements in
solid mechanics are the truss and beam elements.
2. Two-dimensional elements: It is made from minimum of 3 or 4
nodes to maximum of 10 or 12 nodes. Triangular elements and
quadrilateral elements are good examples for two-dimensional
elements. Triangular elements are made of 3 nodes and
quadrilateral elements are made of 4 nodes. Two-dimensional
elements can be modeled to solve stress and strain problems.
3. Three-dimensional elements: It is made from minimum of 4 or
8 nodes to maximum of 20 or 32 nodes. Tetrahedral elements
and Hexahedral elements are good examples for 3 dimensional
elements. Tetrahedral elements are made of 4 nodes and
Hexahedral elements are made of 8 nodes. Three-dimensional
elements can solve large number of problems.
 Element type According to Shape
1. Linear elements: These elements have nodes at the ends. These
elements are made of straight lines which connecting all the nodes
of an element. It has the minimum number of nodes in 1D, 2D and
3D elements. It requires less memory and time in modeling the
continuum and analyzing it. It is less expensive. It cannot support
curved elements much compared to other two types.
2. Quadratic elements: These elements have nodes at the ends as
well as one in the middle of the all line segments, which forms
elements by connecting all nodes. The node in the middle defines
the curvature. It is somewhat complex than linear type. But it can
support curved elements. It requires more memory and time and
more expensive than linear type.
3. Cubic elements: These elements have nodes at the end as well
as two in between end nodes. It has maximum number of nodes in
1D, 2D and 3D elements. It is most complex one compared to
other. It can support all complex elements, but requires more
memory and time compared to other, and most expensive one.
 MESH GENERATION
Two types of meshing are,
1. Manual meshing: In manual mesh generation the analyst
discretizes the simplified geometry of the object to be
studied that is the geometric model of the object, into
nodes and elements. Nodes are defined by specifying their
coordinates, while element connectivity defines the
elements. Manual meshing is inefficient; error prone,
meshing data can be grows rapidly and become confusing
for complex objects especially for three-dimensional ones.
2. Automatic meshing: It refers to the automatic creation
and numbering of nodes and elements based on a minimal
amount of user supplied data. Automatic mesh generation
reduces errors, and saves a great deal of user time,
therefore reducing the FEA cost.
 Requirements of a good mesh
1. Nodal locations should be precise and should not go beyond the
boundary. It must lie inside or on the boundaries of the model.
2. Various element types and shapes should be available to provide user
with more flexibility to meet the compatibility and requirements.
3. Mesh gradation or mesh smoothing and density control should be possible
for users to control the mesh size.
4. To convert from one element type to another should be possible for user.
5. Element aspect ratio (can be defined as the ratio between the elements
maximum length to the elements minimum length.) should be close to one
for better results.
6. Mesh geometry and topology or mesh orientation should be uniform. Eg.
For a cup model, the orientation of all cavity elements and all core
elements should be uniform.
7. It should be compatible with different mesh generation types. Eg. mid
plane meshing, fusion meshing and solid meshing.
8. The time taken to generate mesh and the time taken to perform FEA
should be less. Mesh generation method should optimize the mesh and
minimizes the number of nodes and elements to reduce time and memory
space requirements.
STAGES IN FEA PROGRAM

Three essential stages of Finite

Element Analysis are,
1.Pre-Processing
2.Analyzing the Model
3.Post-Processing
 1. Pre-processing
This involves the preparation of the model data. The pre-
processor is a program, which enables the engineer to
build a geometric model of a component design. From this
model, the required mesh of finite elements may be
generated. Required inputs to the preprocessor include;

• Geometric parameters: Eg. Type of elements, nodal

coordinates, variation of mesh density, etc.
• Loading characteristics: Eg. Magnitudes, positions
and directions of point loads, pressures; thermal loads,
centrifugal loads, frequency and dependent forces, etc.
• Boundary conditions: Eg. Positions and directions of
nodal fixities, rotational axes and frictional resistances,
etc.
• Material properties: Eg. Young’s Modulus, Poisson ratio,
density, Coefficient of friction, Coefficient of expansion, etc.
Geometric Parameters
Loading Characteristics
Material Properties
Boundary Conditions
 2. Analyzing the model

After the preparation of the model

data, the analysis is executed to
get the result
 3. Post-processing

The post-processor is a program,

which provides the engineer with tools
to access the results of the model
analysis. Analyzed results output from
the post-processor may be in either
data form or graphical display.
 3. Post-processing
Typical post-processor output include;

 Printed nodal displacement values.

 Printed element stress values.
 Graphical display of magnified displacements
by a stated multiplication factor.
 Graphical display of stress contours.
 Color or tone variation of element display
according to stress range values.
 Animated displays of moving displacements and
varying element patterns for dynamic loading
analysis
3. Post-processing
Some Post-processing Results
Some Post-processing Results
Some Post-processing Results
Some Post-processing Results
Some Post-processing Results
Some Post-processing Results
Some Post-processing Results
Some Post-processing Results
Some Post-processing Results
Some Post-processing Results
Some Post-processing Results
Some Post-processing Results
Some Post-processing Results
Some Post-processing Results
Factors to be considered in FEA
when making decisions are

1.Type of analysis.
2.The number of nodes.
3.The degrees of freedom at each node.
4.The element shape and type.
5.The material type.
6.The external loads.
7.The boundary conditions.
8.Interpretation of the results.
 TYPES OF ANALYSIS
1. Static and Dynamic analysis: A structural model, thus created
can be used to predict the behavior of the real structure, under the
action of external forces. The response is usually measured in
terms of deflection and stress. The response is static if the loads
are static. This analysis is called static analysis. When the loads are
vary with time the analysis is called dynamic analysis.
2. Linear and non-linear analysis: If the properties of the structure
such as stiffness remain constant during the entire analysis, the
analysis is called linear analysis. If these properties vary, the
analysis is called non-linear analysis.
3. Thermal analysis: FEA can be used for several design and
analysis problems involving thermal stresses, thermal
displacements, heat flow, temperature distribution, etc.
4. Fluid flow analysis: Finite element analysis can solve several
types of fluid flow problems.
5. Field analysis: Problems in magnetic and acoustic can be solved
by FEA.
 DISADVANTAGES OF FEA
1. Likelihood of errors occurring in system codes due
to their increasing size and complexity.
2. Lack of standardization between system codes of
many software packages now in use.
3. Deficiencies in the individual elements.
4. Selection of unsuitable element types.
5. Poor assessment of output data.
6. Masking of important features by the output post-
processor.
7. Inadequate understanding of the assumptions and
limitations of the FEA technique.
8. Poor representation of the component by the FEA
model.
Meshing types available
in Moldflow are

1.Mid Plane Mesh

2.Fusion Mesh
3.Solid Mesh
Types of Analysis in Moldflow

1.Fill
2.Flow
3.Cool
4.Warp
5.Stress
6.Runner balancing
7.Best gate location
8. Molding window
 Gate Location Analysis

It provides the suitable gate location

based on uniformity in filling (all part
extremities to be filled at same time).
 Runner Balancing Analysis

It gives suitable runner size based

on the part distance from the sprue
to each impression (so that each
impression at different distance
from sprue will fill at same time.)
 Molding Window Analysis

• It provides the suitable range processing

parameter for the moulding based on input
data.
• The processing parameter includes injection
time, Mold temperature, Melt temperature.
• The designer can vary the three parameter
and select the suitable / optimum value to get
a best quality in the product.
 Fill Time Analysis provides
 Injection time
 Injection pressure
 Melt temperature
 Mold surface temperature
 Clamp force required
 Fill rate
 Temperature of the melt at flow fronts
 Air traps
 Weld line
 Volume of fill
 Frozen layer
 Shear Stress
 Cooling Analysis
Cooling phase is occur after fill and packing phase.
So Cooling analysis is to be done along with Fill &
Pack.
It gives the following results in addition to the fill
analysis;

• Coolant inlet & Outlet temperatures

• Temperature of the moulding at cavity & core
surfaces (to findout the evennes in cooling).
• Velocity, Renolds no, of the coolant.
 Warp analysis

It is to be done along with Fill + Pack +

Cool.
It gives warpage occurred in the moulding
due to the variations in the moulding
surface temperature, etc.
Types of Mesh available in Moldflow

• Midplane – For uniform

wall thickness parts.
• Fusion (Dual Domain) – For
variable wall thickness & thick
parts.
• 3D. – For solid components
Comparision of Mesh
Meshing Types available

• Automatic
• Manual
 Element Types available

• Beam element – For feed

systems (1D element)
• Triangular – For Mid plane &
Dual domain mesh (2D element)
• Tetrahedron – For solid mesh
(3D element).
Mesh Corrections available in Moldflow

• Mesh Gradation or smoothening (editing the

element size)
• Aspect ratio correction
• Overlapping / intersected mesh correction.
• Free edges / manifold edge error corrections.
• Adjustment of nodes & elements can be done
more user friendly.
• Orientation correction
• Thickness correction, etc.
THANK YOU