LECTURE NOTE: EML 4500

MACHINE DESIGN AND ANALYSIS

Nam Ho Kim
Department of Mechanical & Aerospace Engineering
College of Engineering
University of Florida
P.O. Box 116250
Gainesville, FL 32611

CONTENTS

CONTENTS..................................................................................................................................... I
FIGURE LIST .............................................................................................................................. III
TABLE LIST ................................................................................................................................ VI
CHAP 0.
0.1.
0.2.
0.3.
0.4.
CHAP 1.
1.1.
1.2.
1.3.
1.4.
CHAP 2.
2.1.
2.2.
2.3.
2.4.
2.5.
2.6.
CHAP 3.
3.1.
3.2.
3.3.
3.4.
3.5.
3.6.
CHAP 4.
4.1.
4.2.
4.3.
4.4.
4.5.
4.6.
4.7.

MATHEMATICAL PRELIMINARY.....................................................................1
VECTOR AND MATRIX NOTATIONS ..................................................................................1
VECTOR-MATRIX CALCULUS ...........................................................................................3
MATRIX EQUATION ..........................................................................................................8
EXERCISE .........................................................................................................................9
STRESS-STRAIN ANALYSIS ..............................................................................11
STRESS ...........................................................................................................................11
STRAIN ...........................................................................................................................28
STRESS-STRAIN RELATIONSHIP ......................................................................................32
EXERCISE .......................................................................................................................41
DESIGN CRITERIA...............................................................................................47
PRELIMINARY .................................................................................................................47
DISTORTION ENERGY THEORY (VON MISES, 1913) ........................................................50
THE MAXIMUM SHEAR STRESS CRITERION (TRESCA, 1864) ..........................................52
MAXIMUM PRINCIPAL STRESS THEORY (RANKINE) .......................................................52
SAFETY FACTOR .............................................................................................................53
EXERCISE .......................................................................................................................57
TRUSS FINITE ELEMENT ..................................................................................59
TRUSS ELEMENT IN ONE-DIMENSION .............................................................................59
TRUSS ELEMENT IN TWO-DIMENSION ............................................................................64
TWO-DIMENSIONAL TRUSS ANALYSIS USING I-DEAS ..................................................78
TRUSS ELEMENT IN THREE-DIMENSION .........................................................................80
PROJECT #1 ....................................................................................................................84
EXERCISE .......................................................................................................................85
FINITE ELEMENT ANALYSIS WITH BEAM .................................................89
TOTAL POTENTIAL ENERGY OF BEAM ............................................................................89
FINITE ELEMENT APPROXIMATION .................................................................................91
APPROXIMATION OF THE TOTAL POTENTIAL ENERGY ....................................................95
PRINCIPLE OF MINIMUM TOTAL POTENTIAL ENERGY ....................................................97
CALCULATION OF ELEMENT MOMENTS, SHEAR FORCES, AND STRESSES .......................98
FRAME STRUCTURE ......................................................................................................103
FRAME ANALYSIS USING I-DEAS................................................................................105

4.8.
CHAP 5.
5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
5.7.
CHAP 6.
6.1.
6.2.
6.3.
6.4.
6.5.
6.6.
CHAP 7.
7.1.
7.2.
7.3.
7.4.
7.5.
7.6.

EXERCISE .....................................................................................................................112
FINITE ELEMENT ANALYSIS USING I-DEAS .............................................113
FINITE ELEMENT ANALYSIS PROCEDURE .....................................................................113
PRELIMINARY ANALYSIS ..............................................................................................114
PRE-PROCESSING ..........................................................................................................114
SIMULATION (MODEL SOLUTION) ................................................................................118
POST-PROCESSING ........................................................................................................118
STRESS CONCENTRATION AROUND A HOLE ..................................................................119
PROJECT #2 ..................................................................................................................126
TWO-DIMENSIONAL ELASTICITY ...............................................................127
TYPES OF TWO-DIMENSIONAL PROBLEMS ...................................................................127
PRINCIPLE OF MINIMUM TOTAL POTENTIAL ENERGY ..................................................130
CONSTANT STRAIN TRIANGULAR (CST) ELEMENT ......................................................131
FOUR NODE RECTANGULAR ELEMENT .........................................................................140
FOUR NODE ISO-PARAMETRIC QUADRILATERAL ELEMENT..........................................144
EXERCISE .....................................................................................................................159
INTRODUCTION TO DESIGN OPTIMIZATION ..........................................161
INTRODUCTION .............................................................................................................161
OPTIMALITY CONDITION ..............................................................................................164
CONVEX PROBLEM .......................................................................................................171
NUMERICAL METHOD ..................................................................................................173
PROJECT#3 DESIGN OPTIMIZATION OF BRACKET .........................................................176
EXERCISE .....................................................................................................................180

REFERENCES............................................................................................................................181
INDEX..........................................................................................................................................183

FIGURE LIST

Figure 0.1 Vector product ...................................................................................................5

Figure 1.1 Deformation of a spring under axial force.......................................................11
Figure 1.2 Surface traction acting on a plane....................................................................12
Figure 1.3 Equilibrium of the truss component under the axial force...............................13
Figure 1.4 Normal and shear stresses at a point P.............................................................14
Figure 1.5 Stress components in Cartesian coordinate system..........................................15
Figure 1.6 Stress vector and stress components acting on faces of an infinitesimal
tetrahedron, cutting from the body in Figure 1.2.......................................................17
Figure 1.7 Moment equilibrium of shear stress at a point.................................................20
Figure 1.8 Coordinate transformation of stress .................................................................25
Figure 1.9 Coordinate transformation of Example 1.6......................................................27
Figure 1.10 Maximum shear stress....................................................................................28
Figure 1.11 Definition of strain.........................................................................................29
Figure 1.12 Deformation and strain ..................................................................................31
Figure 1.13 Uniaxial Tension Test ....................................................................................33
Figure 1.14 Stress-strain diagram for a typical ductile material in tension.......................34
Figure 1.15 Stress variations in infinitesimal components................................................38
Figure 1.16 Boundary value problem................................................................................39
Figure 1.17 Cantilever beam bending problem .................................................................40
Figure 1.18 Thin plate under self weight ..........................................................................46
Figure 2.1 Material failures due to relative sliding ...........................................................47
Figure 2.2 Stress-strain curve and the strain energy .........................................................48
Figure 2.3 Distortion energy theory ..................................................................................51
Figure 2.4 The maximum shear stress theory....................................................................52
Figure 2.5 The maximum principal stress theory..............................................................53
Figure 2.6 Bracket structure ..............................................................................................55
Figure 2.7 Shaft under various loads.................................................................................57
Figure 3.1 Truss component..............................................................................................59
Figure 3.2 One-dimensional truss finite element ..............................................................60
Figure 3.3 Two-bar truss structure ....................................................................................64
Figure 3.4 Local and global coordinate system.................................................................65
Figure 3.5 Local coordinate systems of two-bar truss structure........................................66
Figure 3.6 Two-dimensional coordinate transformation...................................................69
Figure 3.7 Two-bar truss structure ....................................................................................73
Figure 3.8 Local coordinates of element A........................................................................73
Figure 3.9 Local coordinates of element B........................................................................74
Figure 3.10 Three-dimensional coordinate transformation ...............................................80
Figure 3.11 One-dimensional truss element......................................................................83
Figure 3.12 Two-dimensional truss element .....................................................................83

iii

Figure 3.13 Three-dimensional truss element ...................................................................84

Figure 3.14 Twelve member structure ..............................................................................85
Figure 4.1 Cantilevered beam structure ............................................................................90
Figure 4.2 Positive directions for force, moment, displacement, and rotational angle .....91
Figure 4.3 Nodal displacements and rotations for the beam element................................92
Figure 4.4 Shape functions for beam element...................................................................94
Figure 4.5 Minimum point of a quadratic function ...........................................................98
Figure 4.6 One element model with distributed force q....................................................99
Figure 4.7 Transverse displacement of the beam element ..............................................101
Figure 4.8 Error from the one finite element analysis with beam ...................................103
Figure 4.9 Frame structure and finite element ................................................................103
Figure 4.10 Two-dimensional frame structure ................................................................105
Figure 4.11 Finite Element Model of a Frame Structure.................................................110
Figure 4.12 Bending Moment Diagram ..........................................................................111
Figure 4.13 Shear Force Diagram ...................................................................................111
Figure 4.14 Stress Contour Plot for Frame Structure......................................................112
Figure 5.1 Finite Element types ......................................................................................115
Figure 5.2 Part model abstraction ...................................................................................116
Figure 5.3 Mapped and free meshes................................................................................116
Figure 5.4 Force symbol in I-DEAS ...............................................................................117
Figure 5.5 Plate model with a hole..................................................................................119
Figure 5.6 I-DEAS part model ........................................................................................121
Figure 5.7 Applied boundary conditions on the part.......................................................122
Figure 5.8 Finite element model .....................................................................................122
Figure 5.9 Finite element analysis result (maximum principal stress)............................123
Figure 5.10 Finite Refined finite element model ............................................................124
Figure 5.11 Finite element analysis result (refined model 1)..........................................124
Figure 5.12 Finite element model (refine model 2).........................................................125
Figure 5.13 Finite element analysis result (refine model 2)............................................125
Figure 5.14 Design domain and boundary condition for the bracket ..............................126
Figure 6.1 Thin plate with in-plane applied forces. Beam can be used for similar purpose
.................................................................................................................................128
Figure 6.2 Dam structure with plane strain assumption..................................................129
Figure 6.3 CST element ..................................................................................................131
Figure 6.4 Applied surface traction along side 1-2 .........................................................134
Figure 6.5 Cantilever Plate..............................................................................................137
Figure 6.6 Four-node rectangular element ......................................................................140
Figure 6.7 Four-node rectangular element ......................................................................143
Figure 6.8 Three-dimensional surface plots pf shape functions for a rectangle..............143
Figure 6.9 Four-node quadrilateral element for plane stress/strain.................................144
Figure 6.10 Four-node quadrilateral element ..................................................................146
Figure 6.11 Element shape obtained from the iso-parametric mapping..........................147
Figure 6.12 Four-node quadrilateral element ..................................................................147
Figure 6.13 Element shape obtained from the iso-parametric mapping..........................148
Figure 6.14 Recommended ranges of internal angles in a quadrilateral element............148

Figure 6.15 Coordinates for evaluation of boundary integrals........................................152

Figure 6.16 Evaluation of work done by applied pressure along side 2-3 ......................153
Figure 6.17 Gauss integration points in two-dimensional parent elements.....................156
Figure 7.1 Structural design optimization procedure ......................................................161
Figure 7.2 Design parameters for beam cross-section.....................................................162
Figure 7.3 Design of a beer can.......................................................................................164
Figure 7.4 Design problem with inactive inequality constraint ......................................166
Figure 7.5 Design problem with active inequality constraint..........................................167
Figure 7.6 Design problem with equality constraint .......................................................167
Figure 7.7 Convex and non-convex sets .........................................................................172
Figure 7.8 Convex function.............................................................................................172
Figure 7.9 Descent direction ...........................................................................................174
Figure 7.10 Line search...................................................................................................175
Figure 7.11 Geometry of a bracket (unit mm).................................................................177
Figure 7.12 Finite element mesh of a bracket .................................................................178
Figure 7.13 Parameter study results ................................................................................178
Figure 7.14 Design optimization history.........................................................................179
Figure 7.15 Design optimization results..........................................................................180

TABLE LIST

Table 1.1 Description of stress components......................................................................16

Table 1.2 Comparison of stress and strain ........................................................................32
Table 1.3 Explanations of uniaxial tension test.................................................................34
Table 6.1 Gauss quadrature.............................................................................................155
Table 7.1 Lower and upper bounds of design parameters (unit mm)..............................177

CHAP 0. MATHEMATICAL PRELIMINARY

Since vector and matrix calculus is repeatedly used during finite element formulation,
it is worth to review it. Although the prerequisite of the class covers elementary calculus
and linear algebra, a brief summary of mathematical formulas is provided for the
convenience of students. Readers who are interested in depth linear algebra are referred
to literature [1] and [2].

0.1. Vector and Matrix Notations

Vector
A vector is a collection of scalars and is defined using a bold typeface with
parenthesis, as
a1
a

{a} = 2
#
a N

(0.1)

which is a N-dimensional vector. By default, in this text all vectors are considered as
column vectors. For the simplicity of notation, a geometric vector in the two- or threedimensional space is denote by a bold typeface without parenthesis, i.e.,
ax

a = a y ,
a
z

or

ax
a=
a y

where ax, ay, and az are components of the vector a in the x-, y-, and z-direction,
respectively. In order to save space, the above column vector a can be written as a = {ax,
ay, az}T in which { }T denotes a transpose of a vector. The above three-dimensional
geometric vector can also be denoted using a unit vector in each coordinate direction. Let
i, j, and k be the unit vectors in x-, y-, and z-direction, respectively, them
a = ax i + a y j + az k

(0.2)

Finite Element Analysis and Design

Matrix
A matrix is a collection of vectors and is defined using a bold typeface with bracket.
For example, let a matrix [M] be a collection of K number of column vectors {mi}, i = 1,
, K. Then, the matrix [M] can be denoted by
[M ] = [{m1} {m2 } " {mK }]

where
m1i
i
m
i
{m } = 2 ,
#
mNi

i = 1,", N

By extending each component of vectors {mi}, the matrix [M] can be denoted using NK
components, as
M 11
M
[M ] = 21
#

M N1

M 12
M 22
#
MN2

" M 1K
" M 2K

%
#

" M NK

(0.3)

where M ij = mij is a component of the matrix. In such a case, the dimension of the matrix
[M] is NK. When N = K, it is called a rectangular matrix.

Transpose of a Matrix
The transpose of a matrix can be obtained by switching the rows and columns of the
matrix. For example, the transpose of the matrix [M] in Eq. (0.3) can be calculated by
M 11
M
[M ]T = 12
#

M 1K

which is now KN dimensional matrix.

M 21
M 22

#
M 2K

" M N1
" MN2

%
#

" M NK

(0.4)

Chap 0. Mathematical Preliminary

Symmetric Matrix
A matrix is called symmetric when the matrix and its transpose are identical. As is
clears from its definition, only a rectangular matrix can be a symmetric. For example, a
matrix [S] is called symmetric, if
M 11
M
[S] = [S]T = 12
#

M 1N

M 12
M 22

#
M2N

" M 1N
" M 2N

%
#

" M NN

(0.5)

Diagonal and Identity Matrix

A diagonal matrix is a special case of a symmetric matrix of which all off-diagonal
components are zero. An identity matrix is a diagonal matrix of which all diagonal
components are one. For example, the identity matrix in the three-dimensional space is
1 0 0
[I] = 0 1 0

0 0 1

(0.6)

0.2. Vector-Matrix Calculus

Vector and Matrix Operations
Addition and subtraction between vectors and matrices are possible when the
dimensions of them are the same. Let {a} and {b} are N-dimensional vectors. Then, the
addition and subtraction of these two vectors are defined as
{c} = {a} + {b},

ci = ai + bi , i = 1,", N

{d} = {a} {b},

d i = ai bi , i = 1,", N

(0.7)

Note that the dimensions of vectors {c} and {d} are the same as that of vectors {a} and
{b}.
If a scalar is multiplied with a vector, then the scalar is multiplied to all of its
components, as
k{a} = {ka1 ka2 " ka N }T

(0.8)

Finite Element Analysis and Design

Similar operations can be defined for matrices. Let [A] and [B] are NK dimensional
matrices. Then, the addition and subtraction of these two matrices are defined as
[C] = [ A ] + [B],

Cij = Aij + Bij , i = 1,", N , j = 1,", K

[D] = [ A ] [B],

Dij = Aij Bij , i = 1,", N , j = 1,", K

(0.9)

Note that the dimensions of matrices [C] and [D] are the same as that of matrices [A] and
[B].
Although the above addition and subtraction are very similar to that of scalars, the
multiplication and division of vectors and matrices are quite different from that of scalars.

Scalar Product
A scalar product (inner product) is similar to the multiplication of scalars. Since the
scalar products between two vectors will frequently appear in this text, it is necessary to
clearly understand notations. Let a and b are three-dimensional geometric vectors defined
by
ax
bx


a = a y and b = by


az
bz

The scalar product between a and b is defined by

a b = a x bx + a y by + az bz

(0.10)

which is summation of the component-by-component multiplications. If a and b are two

geometric vectors, then the scalar product can be written as
a b = a b cos

(0.11)

where is the angle between two vectors.

Norm
A norm represents the magnitude of a vector and is defined using the scalar product.
For example, the norm of a three-dimensional vector a can be defined as
a = aa

(0.12)

Chap 0. Mathematical Preliminary

Note that the norm is always a non-negative scalar and is a length of the geometric
vector. When a = 1 , the vector a is called the unit vector

Vector Product
Different from the scalar product, the result of the vector product becomes another
vector. In the three-dimensional space, the vector product of two vectors a and b can be
defined as
i
j
a b = a1 a2
b1 b2

k
a3
b3

= ( a2 b3 a3b2 )i + ( a3b1 a1b3 ) j + ( a1b2 a2 b1 )k

(0.13)

a2 b3 a3b2

= a3b1 a1b3
a b a b
2 1
1 2

In the conventional notation, the vector product can be defined by

a b = a b sin n

(0.14)

where is the angle between two vectors and n is the unit vector that is perpendicular to
the plane that contains both vectors a and b. The right-hand rule can be used to determine
the positive direction of vector n as shown in Figure 0.1. It is clear from its definitions in
Eqs. (0.13) and (0.14), a a = 0 , and b a = a b .
ab
b
n

Figure 0.1 Vector product

Matrix-Vector Multiplication
The matrix-vector multiplication often appears during finite element analysis. Let
[M] be a 33 matrix defined by

Finite Element Analysis and Design

mxx

[M ] = mxy
mxz

myx
myy
m yz

mzx

mzy
mzz

The multiplication between a matrix [M] and a vector a is defined by

mxx

c = [M ] a = mxy
mxz

mzx a x mxx a x + m yx a y + mzx az

mzy a y = mxy ax + m yy a y + mzy a z
mzz a z mxz a x + m yz a y + mzz a z

m yx
m yy
m yz

(0.15)

which is a 31 column vector. If a conventional notation is used, Eq. (0.15) can be

denoted using
3

ci = M ij a j , i = 1,2,3
j =1

where a1 = ax, a2 = ay, a3 = az, etc.

Since the result of Eq. (0.15) is a vector, it is possible to perform the scalar product of
the above equation with a vector b, yielding
b [ M] a = bx ( mxx a x + m yx a y + mzx az )
+by ( mxy a x + m yy a y + mzy az ) + bz ( mxz ax + m yz a y + mzz az )

(0.16)

which is a scalar.

Matrix-Matrix Multiplication
The matrix-matrix multiplication is a more general case of Eq. (0.15). For 33
matrices, the matrix-matrix multiplication can be defined as
[C] = [ A ][B]

(0.17)

where [C] is also a 33 matrix. Using the component notation, Eq. (0.17) is equivalent to
3

C IJ = AIK BKJ ,
K =1

I = 1,2,3,

J = 1,2,3

(0.18)

Chap 0. Mathematical Preliminary

Determinant of a Matrix
Even if the general definition of the determinant is complicated, a simple expression
can be possible if we consider a 22 or a 33 matrix. The determinant of a 22 matrix is
defined as
A =

a11
a21

a12
= a11a22 a12 a21
a22

(0.19)

The determinant of a 33 matrix is defined as

a11

a12

a13

A = a21 a22
a31 a32

a23
a33

(0.20)

= a11 ( a22 a33 a23a32 ) a12 ( a21a33 a23a31 ) + a13 ( a21a32 a22 a31 )

A matrix is called singular when its determinant is zero.

Example 0.1
The following results can be proved using Eq. (0.19)
a b
=0
0 0
ka kb
a b
=k
c d
c d
a b
c d
b
=
=
c d
a b
d
a b
= 0,
ka kb

a
c

a ka
=0
b kb

a+e b+ f
a b e f
=
+
= ( ad bc ) + ( ed cf )
c
d
c d c d

Inverse of a Matrix
A simple expression can be obtained for the inverse of a matrix when the dimension
is 22.

Finite Element Analysis and Design

a12
a
1 a22 a12
[ A ] = 11
=

A a21 a11
a21 a22
1

(0.21)

It can be easily verified that [A][A]1 = [I]. When a matrix is singular ( A = 0 ), then the
inverse of the matrix does not exists.

0.3. Matrix Equation

Consider the following simultaneous system of equations:
a11 x1 + a12 x2 + " + a1N x N = b1
a21 x1 + a22 x2 + " + a2 N x N = b2

#
a N 1 x1 + a N 2 x2 + " + a NN x N = bN

(0.22)

Equation (0.22) has an N number of unknowns (x1, x2, , xN) and an N number of
equations. If all equations are independent, then Eq. (0.22) has a unique solution.
Equation (0.22) can be equivalently denoted using the matrix notation, as
[ A ] {x} = {b}

(0.23)

where
a11 a12
a
a22
[ A ] = 21
#
#

aN 1 aN 2

" a1N
x1
b1

b
x
" a2 N
, {x} = 2 , {b} = 2
% #
#
#

" a NN
x N
bN

When the matrix [A] and the vector {b} is known, the solution {x} can be obtained by
multiplying [A]1 at both sides of the equation, as
[ A ]1[ A ] {x} = [ A ]1 {b}
[I] {x} = [ A ]1 {b}
{x} = [ A ]1 {b}

Note that [I] {x} ={x}. Thus, a unique solution can be obtained if [A]1 exists or
equivalently, the matrix [A] is not singular.

Chap 0. Mathematical Preliminary

0.4. Exercise
0.1

Write a transpose of the following matrix:

1 7 2
[ T] = 3 4 3

6 5 7

0.2

Show that the matrix [S] = [T] + [T]T is a symmetric matrix.

0.3

Calculate [C] = [A] + [B] and [D] = [A] [B] when

1 7 2
[ A ] = 3 4 3 ,

6 5 7

3 7 2
[ B] = 2 1 8

7 4 5

0.4

Calculate c = a b when a = {1, 4, 6}T and b = {4, 7, 2}T.

0.5

Calculate the norm if vector a in Exercise 0.4.

0.6

Calculate the vector product of a and b in Exercise 0.4 using Eq. (0.13) and
Eq. (0.14), and show that two results are identical.

0.7

Calculate the matrix-vector multiplication [T] a between [T] in Exercise 0.1 and
a in Exercise 0.4. In addition, calculate b[T] a using b in Exercise 0.4.

0.8

Calculate the matrix-matrix multiplication of [A] and [B] in Exercise 0.3

0.9

Calculate the determinant of the following matrices:

4 2
[A ] =
,
3 7

1 3 2
[B] = 1 4 5

2 6 7

0.10

Calculate the inverse of the matrix [A] in Exercise 0.9.

0.11

Solve the following simultaneous system of equations using the matrix method:
4 x1 + 3x2 = 3
x1 + 3x2 = 3